ZP16-2400 SPRC Maintenance Manual (Mechanical)

TWO (2) QUAYSIDE CONTAINER CRANES
FOR
SPRC ,COLOMBIA
ZP16-2400
MAINTENANCE MANUAL
(MECHANICAL PART )
SHANGHAI ZHENHUA HEAVY INDUSTRIES CO., LTD,
Dec, 2016
Quayside Container Crane Configuration
该 Shanghai Zhenhua Heavy Catalogue
Industries Co.,Ltd. and Maintenance Manual
CATALOGUE
CHAPTER 1 BRIEF INTRODUCTION OF QUAYSIDE CRANE ............................. 1-1
1.1 OUTLINE AND MAIN PARAMETERS FOR QUAYSIDE CONTAINER CRANE ...................................... 1-1
1.2 CONFIGURATION OF THE CRANE STEEL STRUCTURE .................................................................. 1-2
1.3 DRIVE MECHANISM ON CRANE .................................................................................................... 1-3
1.3.1 Main hoist drive.................................................................................................................................................................... 1-3
1.3.1.1 Main hoist reeving system ............................................................................................................................................... 1-5
1.3.1.2 INTERLOCKS FOR MAIN HOIST DRIVE .......................................................................................................................... 1-6
1.3.1.3 POSITIONING LIMITS FOR MAIN HOIST DRIVE .......................................................................................................... 1-7
1.3.1.4 TRIM-LIST-SKEW AND SNAG PROTECTION DEVICE ..................................................................................................... 1-7
1.3.2 Boom hoist system ............................................................................................................................................................... 1-9
1.3.2.1 BOOM HOIST DRIVE ....................................................................................................................................................... 1-9
1.3.2.2 BOOM HOIST ROPE REEVING SYSTEM .........................................................................................................................1-10
1.3.2.3 BOOM HOIST INTERLOCKS ...........................................................................................................................................1-10
1.3.2.4 BOOM TRAVELING LIMITS ............................................................................................................................................ 1-11
1.3.3 Trolley travel system..........................................................................................................................................................1-12
1.3.3.1 TROLLEY TRAVEL DRIVE ..............................................................................................................................................1-12
1.3.3.2 TROLLEY ROPE REEVING SYSTEM ...............................................................................................................................1-13
1.3.3.3 TROLLEY INTERLOCKS LIMITS ....................................................................................................................................1-13
1.3.3.4 TROLLEY TRAVELING LIMITS .......................................................................................................................................1-13
1.3.3.5 TROLLEY TRAVEL ROPE TENSIONER ...........................................................................................................................1-14
1.3.3.6 TROLLEY .......................................................................................................................................................................1-15
1.3.3.7 OPERATOR’S CAB ..........................................................................................................................................................1-16
1.3.4 Gantry.....................................................................................................................................................................................1-16
1.3.4.1 GANTRY TRAVEL DRIVE ...............................................................................................................................................1-16
1.3.4.2 INTERLOCKS FOR GANTRY DRIVE ..............................................................................................................................1-18
1.3.4.3 GANTRY MAINTENANCE CAB .....................................................................................................................................1-18
1.4 CRANE SAFETY FACILITIES....................................................................................................... 1-19
1.4.1 CRANE STOWAGE DEVICE AND T IE-DOWN DEVICE ....................................................................................................1-19
1.4.2 BOOM STOWAGE DEVICE .................................................................................................................................................1-19
1.4.3 SHIP COLLISION PROTECTION .........................................................................................................................................1-20
1.4.4 OBSTRUCTION LIGHTS ............................................................................................................................... 1-20
1.5 AUXILIARY EQUIPMENTS ON CRANE ........................................................................................ 1-20
1.5.1 POWER CABLE REEL ........................................................................................................................................................1-20
1.5.2 TROLLEY FESTOON SYSTEM ...........................................................................................................................................1-21
1.6 Maintenance equipment .................................................................................................................................................. 1-21
1.6.1 MACHINERY HOUSE SERVICE CRANE .............................................................................................................................1-21
1.6.2 SERVICE CRANE OUTDOORS............................................................................................................................................1-21
1.6.3 WIRE ROPE RE-REEVING DEVICE ..................................................................................................................................1-21
1.7 WALKWAYS, ACCESS AND ELEVATOR ........................................................................................ 1-24
1.7.1 WALKWAYS AND PLATFORM...........................................................................................................................................1-24
1.7.2 ELEVATOR .........................................................................................................................................................................1-25
1.8 HANDLING SYSTEM ................................................................................................................... 1-26
1.8.1 SPREADER .........................................................................................................................................................................1-26
1.8.2 HEADBLOCK .....................................................................................................................................................................1-26
1.8.3 OVER-HEIGHT ADAPTER ..................................................................................................................................................1-26
1.8.4 HOOK BEAM .....................................................................................................................................................................1-26
1
CHAPTER 2 CRANE MAINTENANCE INSTRUCTIONS ........................................ 2-1

2.1 GENERAL ..................................................................................................................................... 2-1
2.2 CAUTIONS AND SAFETY NOTES .................................................................................................... 2-1
2.2.1 SAFETY RULES OF OPERATION ......................................................................................................................................... 2-2
2.2.2 SAFETY RULES DURING REPAIRING OR MAINTENANCE ............................................................................................... 2-2
2.2.3 SAFETY RULES AFTER MAINTENANCE / REPAIR WORK............................................................................................... 2-2
2.3 CLEANLINESS .............................................................................................................................. 2-3
2.3.1 MAJOR METHODS OF CLEANLINESS ................................................................................................................................ 2-3
2.3.1.1 DRY CLEANING .............................................................................................................................................................. 2-3
2.3.1.2 USING CLEANSER ........................................................................................................................................................... 2-3
2.3.2 MAIN CLEANING WORK ................................................................................................................................................... 2-4
2.3.2.1 CLEANLINESS OF COMMON PARTS ............................................................................................................................... 2-4
2.3.2.2 CLEANLINESS OF THE ELECTRIC ELEMENTS AND SYSTEM ........................................................................................ 2-4
2.3.2.3 CLEANLINESS OF THE HYDRAULIC SYSTEM................................................................................................................ 2-5
2.4 FASTENING ................................................................................................................................... 2-7
2.4.1 GRADE OF FASTENERS...................................................................................................................................................... 2-7
2.4.2 INSPECTION OF BOLTS ...................................................................................................................................................... 2-7
2.4.3 PROCESS FOR BOLT’S REPLACEMENT AND TIGHTENING............................................................................................... 2-9
2.4.4 ANTI-LOOSING METHODS FOR BOLTS ............................................................................................................................2-12
2.4.5 PIN CONNECTION .............................................................................................................................................................2-12
2.5 LUBRICATION ............................................................................................................................ 2-13
2.5.1 SUMMARIZATION .............................................................................................................................................................2-13
2.5.2 LUBRICANT ......................................................................................................................................................................2-13
2.5.3 LUBRICANT REPLACEMENT STANDARD ........................................................................................................................2-15
2.5.4 LUBRICATION PROCEDURE ...................................................................................................................................2-15
2.5.5 LUBRICATING POINTS LAYOUT .......................................................................................................................................2-15
2.5.6 LUBRICATING FREQUENCY .............................................................................................................................................2-17
2.6 PREVENTION AND INSPECTION .................................................................................................. 2-21
2.6.1 SUMMARIZE .....................................................................................................................................................................2-21
2.6.2 INSPECTION OF TEMPERATURE RISE...............................................................................................................................2-22
2.6.3 INSPECTION OF ABNORMAL NOISE .................................................................................................................................2-22
2.6.4 INSPECTION OF ABNORMAL VIBRATION.........................................................................................................................2-22
2.6.5 INSPECTION OF CRACK ....................................................................................................................................................2-23
2.6.6 INSPECTION OF RAIL & RAIL CLIPS ................................................................................................................................2-23
2.6.7 INSPECTION OF GANTRY & TROLLEY TRAVEL WHEEL..................................................................................................2-26
2.6.8 INSPECTION OF ROPE SHEAVES, DRUMS, IDLER AND SLAP BLOCK..............................................................................2-28
2.6.9 INSPECTION OF THE SPREADER.......................................................................................................................................2-28
2.6.10 INSPECTION OF HOOK AND TWIST LOCK PIN ...............................................................................................................2-29
2.6.11 INSPECTION OF HYDRAULIC HANDSPIKE BRAKE ........................................................................................................2-29
2.6.12 INSPECTION OF BRAKE DISC .........................................................................................................................................2-30
2.6.13 INSPECTION OF SHAFT AND AXLE SLEEVE ...................................................................................................................2-31
2.6.14 INSPECTION OF OIL SEAL ...............................................................................................................................................2-31
2.6.15 BEARING UNIT INSPECTION ..........................................................................................................................................2-31
2.6.16 INSPECTION PROCEDURE OF KEY AND KEYWAY .........................................................................................................2-31
2.6.17 INSPECTION OF CONSUMABLE PARTS ...........................................................................................................................2-33
2.6.18 INSPECTION OF STEEL STRUCTURAL MEMBERS ..........................................................................................................2-33
2.6.19 INSPECTION OF ALL SAFETY PROTECTIONS .................................................................................................................2-34
2.7 CHECK LIST ............................................................................................................................... 2-34
2
CHAPTER 3 SOME IMPORTANT PARTS REPLACEMENT.................................... 3-1

3.1 GENERAL ..................................................................................................................................... 3-1
3.1.1 ATTENTION ........................................................................................................................................................................ 3-1
3.2 BEARING BLOCK REPLACEMENT ................................................................................................ 3-1
3.2.1 PREPARATION .................................................................................................................................................................... 3-1
3.2.2 REPLACEMENT PROCEDURE ............................................................................................................................................ 3-1
3.3 MOTOR COUPLING REPLACEMENT ............................................................................................ 3-3
3.3.1 PREPARATION .................................................................................................................................................................... 3-3
3.4 DRUM COUPLING REPLACEMENT................................................................................................ 3-5
3.4.1 PREPARATION .................................................................................................................................................................... 3-5
3.5 MOTOR BRAKE REPLACEMENT ................................................................................................... 3-9
3.5.1 PREPARATION ............................................................................................................................................................................ 3-9
3.5.2 REPLACEMENT PROCEDURE ...................................................................................................................................................3-10
3.5.2.1 A WHOLE BRAKE REPLACEMENT ................................................................................................................................3-10
3.5.2.2 THRUSTER REPLACEMENT ...........................................................................................................................................3-11
3.5.2.3 SPRING SQUARE TUBE REPLACEMENT ........................................................................................................................ 3-11
3.5.2.4 SPRING REPLACEMENT.................................................................................................................................................3-12
3.5.2.5 AUTO COMPENSATE DEVICE REPLACEMENT..............................................................................................................3-12
3.5.2.6 BRAKE GASKET REPLACEMENT ..................................................................................................................................3-13
3.5.2.7 HAND RELEASE DEVICE REPLACEMENT .....................................................................................................................3-13
3.5.2.8 EQUALIZATION NUT REPLACEMENT ...........................................................................................................................3-14
3.6 DRUM BRAKE REPLACEMENT ................................................................................................... 3-15
3.6.1 PREPARATION ...........................................................................................................................................................................3-15
3.6.2.1 HYDRAULIC CYLINDER REPLACEMENT......................................................................................................................3-16
3.6.2.2 BLOCK SPRING REPLACEMENT ....................................................................................................................................3-16
3.7 WHEEL BRAKE REPLACEMENT ................................................................................................. 3-17
3.7.1 PREPARATION ...........................................................................................................................................................................3-17
3.7.2.1 THE WHOLE WHEEL BRAKE REPLACEMENT ...............................................................................................................3-17
3.7.2.2 HYDRAULIC CYLINDER REPLACEMENT......................................................................................................................3-18
3.7.2.4 BLOCK SPRING REPLACEMENT ....................................................................................................................................3-20
3.7.2.5 BLOCK REPLACEMENT .................................................................................................................................................3-20
3.8 GANTRY WHEEL REPLACEMENT ............................................................................................... 3-21
3.8.1 PREPARATION ...................................................................................................................................................................3-21
3.8.2 REPLACEMENT PROCEDURE ...........................................................................................................................................3-21
3.9 TROLLEY WHEEL REPLACEMENT ............................................................................................. 3-23
3.9.1 PREPARATION ...................................................................................................................................................................3-23
3.9.2 REPLACEMENT PROCEDURE ...........................................................................................................................................3-24
3.9.3 ECCENTRIC SLEEVE ASSEMBLE ......................................................................................................................................3-25
3.9.4 TROLLEY WHEEL REPLACEMENT ...................................................................................................................................3-25
3.9.5 WHEEL ADJUSTMENT ANALYSIS .....................................................................................................................................3-26
3.9.6 ILLUSTRATE FOR TROLLEY WHEELS ADJUSTMENT .......................................................................................................3-27
3.10 MAIN HOIST PULLEY REPLACEMENT ...................................................................................... 3-29
3.10.1 PREPARATION .................................................................................................................................................................3-29
3.10.2 REPLACEMENT PROCEDURE .........................................................................................................................................3-29
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CHAPTER 4 WIRE ROPE ............................................................................................ 4-1

4.1 BASIC KNOWLEDGE OF WIRE ROPE ............................................................................................ 4-1
4.1.1 CONSTRUCTION ................................................................................................................................................................ 4-1
4.1.2 CORE .................................................................................................................................................................................. 4-1
4.1.3 TYPE OF LAYING ............................................................................................................................................................... 4-1
4.2 HANDLING OF WIRE ROPE .......................................................................................................... 4-2
4.2.1 TRANSPORTATION AND STORAGE .................................................................................................................................... 4-2
4.2.2 INSTALLATION OF WIRE ROPE .......................................................................................................................................... 4-3
4.3 TERMINATION AND TREATMENT OF WIRE ROPE END ..................................................................... 4-4
4.3.1 THE WIRE ROPE CLIP ........................................................................................................................................................ 4-4
4.3.2 WIRE ROPE CUTTING AND TREATMENT OF ROPE END ................................................................................................... 4-5
4.4 INSPECTION OF WIRE ROPE ........................................................................................................ 4-6
4.4.1 THE FACTORS INFLUENCE THE ROPE LIFE ...................................................................................................................... 4-7
4.4.2 INSPECTION METHOD....................................................................................................................................................... 4-8
4.4.3 WHERE AND WHEN MUST WIRE ROPES BE INSPECTED .................................................................................................4-10
4.4.4 WHAT SHALL BE INSPECTED ...........................................................................................................................................4-10
4.4.5 DISCARD CRITERIA .......................................................................................................................................................... 4-11
4.5 WIRE ROPE LUBRICATION ........................................................................................................ 4-20
4.5.1 IMPORTANCE OF LUBRICATION .......................................................................................................................................4-20
4.5.2 SELECTION OF LUBRICANT .............................................................................................................................................4-20
4.5.3 THE METHOD OF LUBRICANT .........................................................................................................................................4-21
4.5.4 LUBRICATING OF MAIN HOIST AND TROLLEY TOWING WIRE ROPES ...........................................................................4-22
4.5.5 LUBRICATING OF BOOM HOIST WIRE ROPES..................................................................................................................4-23
4.6 ROPE RE-REEVING .................................................................................................................... 4-25
4.6.1 RE-REEVING OF MAIN HOIST ROPE ................................................................................................................................4-27
4.6.2 RE-REEVING OF TROLLEY TOWING ROPE ......................................................................................................................4-29
4.6.3 RE-REEVING OF BOOM HOIST ROPE ...............................................................................................................................4-30
4.6.4 RE-REEVING OF CATENARY TROLLEY ROPE ..................................................................................................................4-32
4.7 ROPE TYPE & SIZE FOR CRANES .............................................................................................. 4-33
CHAPTER 5 QUAYSIDE CONTAINER CRANE INSPECTION REQUIREMENTS
FOR HIGH-ALTITUDE FALL HAZARD .................................................................... 5-1
CHAPTER 6 EXPLANATION OF DRAWING NO. .................................................... 6-1
6.1 DRAW NO'S CHARACTERISTICS .................................................................................................. 6-1
6.2 THE EXPLANATION OF ZPMC DRAWING NO. LABLE .................................................................... 6-1
6.3 ILLUSTRATE HOW TO FIND OUTSOURCING COMPONENTS' TYPE OR PART'S DRAWING NO. ....... 6-3
CHAPTER 7 SAFETY. .................................................................................................. 7-1
7.1 WARNINGS AND SYMBOLS………………………………………….…………….….….…………7-1
7.2 GENERAL PRECAUTIONS……………………………………………………….……….…….….7-2
7.3 GENERAL RULES OF CONDUCT AND SAFETY REGULATIONS. …………………….…………….…7-3
7.4 SAFETY RULES FOR OPERATION……………………..……………………….……….……...…7-4
7.5 SAFETY RULES FOR MAINTENANCE AND REPAIR………………………………………….……..7-6
7.6 CONDUCT IN CASE OF ACCIDENTS AND EMERGENCY…………………………………….………7-7
CHAPTER 8 MAINTENANCE GUIDE OF THE ANTICORROSION COATING IN
PORT MACHINERY EQUIPMENTS. .......................................................................... 8-1
8.1 GENERAL PRINCIPLES ................................................................................................................. 8-1
8.1.1 SCOPE ................................................................................................................................................................................. 8-1
8.2 STANDARD COMPARISON OF COATING RUST ............................................................................... 8-1
8.3 INSPECTION PERIOD AND CONTENT OF DAILY MAINTENANCE .................................................... 8-2
4
8.3 INSPECTION PERIOD AND CONTENT OF DAILY MAINTENANCE .................................................... 8-2

8.3.1 INSPECTION PERIOD .......................................................................................................................................................... 8-2
8.3.2 INSPECTION CONTENT AND MEASUREMENT .................................................................................................................. 8-2
8.4 PAINT FOR MAINTENANCE ........................................................................................................... 8-3
8.4.1 CHOICE OF PAINT BRAND.................................................................................................................................................. 8-3
8.4.2 CHOICE OF COATING ......................................................................................................................................................... 8-3
8.5 COATING SYSTEM INSPECTION AND MAINTENANCE REQUIREMENTS ......................................... 8-4
8.5.1 COATING SYSTEM INSPECTION REQUIREMENTS............................................................................................................. 8-4
8.5.2 COATING SYSTEM MAINTENANCE REQUIREMENTS ....................................................................................................... 8-4
8.5.3 SPECIAL SPECIFICATION ................................................................................................................................................... 8-4
8.6 SAFETY PRECAUTIONS ................................................................................................................. 8-5
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Shanghai Zhenhua Heavy Quayside Container Crane
Industries Co.,Ltd. Chapter ONE
Configuration and Maintenance Manual
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Chapter 1 Brief introduction of quayside crane

1.1 Outline and main parameters for quayside container crane
This quayside container crane has twin-box trolley.

section boom & girder, and a rope-towed The main parameters are below as table 1-1:
Table 1-1：Main Parameters for Quayside Container Crane

Rated Load Under Spreader 65 Hoist Speeds Full Load 90
Capacity(t) Under Hook 80 (m/min) Empty Load 180
Speed
Above Rail 42 Trolley Travel Speed (m/min) 240
Lift Height (m) Total Lift
42+17 Gantry Speed (m/min) 45
Height
Outreach (m) 61
Main Hoist
Back reach (m) 13 Full Load ~2.1
Accelerating
Acceleration Time
Max Operating Sea-side 85
Basic Parameters
(sec)
Speeds
Wheel Load (t) Land-side 68 No Load ~3.8
Trolley Travel Acceleration Time
Sea-side 95.2 ~6
Max Stowed (sec)
Wheel Load (t) Gantry Travel Acceleration Time
Land-side 76 ~6
(sec)
Inside Clearance Between Legs(m) 18 Boom Hoist 0°-80°(Stowed Position) ~5
time One Way 0°-45°(Ship Clearance
~3
Height Under Link Beam(m) 12.46 (min) ≤ Position)
Quantity (pcs) 2
Overall Crane Width from Bumper Hoist
27.2 Power (Kw) 705
to Bumper (m) Motors
Crane Weight (t) ~1250 Rotating Speed (rpm) 900/1800
Setback of WS Trolley Girder
2 Quantity (pcs) 1
Motor Power
Support Beam (m) Trolley

Motors Power (Kw) 270
Anti-Snag Provided Rotating Speed (rpm) 1750
Functions
Special
Quantity (pcs) 16
Gantry
Power (Kw) 20
Motors
Type of Anti-Sway Electrical Rotating Speed (rpm) 1400
Quantity (pcs) 1
Boom
Trim ±3°
Parameter
Hoist Power (Kw) 280

Spreader
List ±5°
Motor
Skew ±5° Rotating Speed (rpm) 1750
s
Single 20′/40′/45′ & Twin-20′ Telescopic

Rail type CR175
Spreader
Gantry Main
Rail type A75 Wheel Diameter(mm) Φ800

Main Data
Data
Trolley
Wheel Diameter(mm) Φ630

Wheel Number on Each Leg (pcs) 8
Wheel Number 4
Weight(t) 23 Driving wheels (pcs) 4
Double Boom Hinges Adopted between Boom and
Stowage Pin Between Crane and Wharf Manual
Trolley Girder
Power Supply on
Stowage Pin Between Boom and A-Frame Manual 13,2KV,60HZ,3/PE
Wharf
1
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1.2 Configuration of the crane steel structure
With a huge volume profile and suffering severe impact ensured by the well-designed steel structure and the
and frequently start-up and braking, a crane is obliged to advanced control system. Most of the structure member
ensure container positioned accurately and handled section is trunk or box except some in tubular shape. The
efficiently at high speed during operation. All these are members of Main structure refer to Figure 1-1.
8 Frame Link Beam

4 Trolley Girder Backstay
12 Outer Boom Forestay

7 Backstays of Apex Beam
Figure 1-1: Crane Steel Structure Overview
11 Inner Boom Forestay
15 Sea-side Sill Beam

3 Trolley Girder
6 Land-side Legs
2 Land-side Sill Beam
14 Sea-side TGSB
10 Sea-side Legs
5 Support of Trolley Girder Backstays
9 Frame Link Beam

1 Land-side TGSB
13 Boom
2
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1.3 Drive mechanism on crane
Travel are provided on the crane and sheltered in a
The four major drive mechanisms: Main Hoist Drive, weatherproof Machienry House except the Gantry Travel
Boom Hoist Drive, Trolley Travel Drive and Gantry as shown in the below Figure 1-2.
Figure 0-1: Major Drive Mechanisms Layout in Machinery Room

1 boom hoist drive 2 trolley travel drive 3 main hoist drive
1.3.1 Main hoist drive
The main hoist drive is located in the machinery house. It motors to the drums by the high speed couplings and
is powered by two variable frequency AC motors drum couplings and amplified through the reducer driving
connected to the reducer input shafts through the flexible the drum and rope to lift or lower the cargo attached
elastomeric type couplings (high speed). Two rope drums under the telescopic spreader or hook beam. The data of
are connected to the output shafts of the reducer through main components refers to Table 1-2.
the two flexible gear couplings (lower speed). The
driving force of this equipment is transmitted from the
3
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Table 0-1: Main Data of Major Components for Main Hoist Drive
Type AG 1PH8 356 Type SF24
Drum Brake
Motor Power 2X705kw Brake Torque 2X192kNm
Rotating speed 900/1800rpm Type AKNXSE 0.88
Type PD63-R11-V25-18-Z2 Motor Coupling Rated Torque 24kNm
Ratio 18.7 Brake Torque 48kNm
Reducer
Rated Output
416kNm Type TTX21
torque Drum Coupling
Type SB28.3-BL450-8 Rated Torque 310kNm
Motor Brake
Braking Torque 2X25.6kNm Wire Rope Diameter Φ30mm
Note: The braking torque of motor brake must be set according to required set torque on the drawing.
3 Motor 4 Drum Coupling 5 Reducer

9 Motor Brake
Figure 1-3 Scheme and Photograph for Main Hoist Drive
6 Motor Coupling 7 Drum 8 Limit Switch Device

2 Drum Brake
1 Drum Bearing Seat
Installed above the main reducer, an emergency drive is capable of hoisting or lowering the spreader
slowly in case the hoist motor or drive control system failed and can not be fixed immediately. Upon the
crane loss of high voltage power while hoisting or lowering, this emergency device can be plugged on the
shore power and continue the operation till the container removed from the spreader or ready for next
step.
4
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1.3.1.1 Main hoist reeving system

The wire ropes reeled out from the drum, then run
through the following route:
Drum→Trim/List/Skew/Snag System on girder rear
end → Sheaves on trolley frame → Sheaves on
head-block → back to Sheaves on trolley frame → Load
cell at boom tip.
The rope ends are tied with four load cells which are
mounted under the sheave blocks respectively at the
boom tip (refer to Figure 1-4). The signal will be
generated by the tension force along the wire ropes then
transmitted to PLC (Programmable Logic Controller) and
CMS (Crane Management System) so that the hanging
load and its eccentricity information can be figured out
and recorded.
Figure 1-4: load cell location
Figure 0-2: Main Hoist Rope Reeving System
1 Load Scaled Clamp Blocks on Boom Tip 2 Sheave Block on Head-block

3 Drum of Main Hoist 4 Trim/List/Skew & Anti-Snag on Girder Rear End
5
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either switch is actuated.
1.3.1.2 Interlocks for main hoist drive
4） Motor thermal switch
Each of the two hoist motors features an embedded
1） Over-speed switch over-temperature switch (one normally closed
External over-speed protection for the main hoist is contact). Actuation of the switch indicates the motor
provided at the end of one drum. Actuation of the
temperature is at fault level. The hoist motion is
switch initiates an emergency stop. The theoretical
inhibited from operating as long as either of the
trip speed setting for the switch is 110% of the
switches is actuated.
motor maximum speed. In order to resume the crane
operation, the switch must be manually reset from 5） Load weighing system
its back once it is tripped. (Refer to Figure 1-6) As Information for the lifted load is provided by the
an optional device, which is connected with the weighing system. The hoist drives also provide
motor shaft end, the incremental encoder can overload indications. Refer to Section 1.3.1.1 for
transmit the real-time speed signal then PLC will more detailed description.
evaluate over-speed or not. (Refer to Figure 1-7)
6） Anti-Snag system
When the snag occurs, the hydraulic system will
enable the snagged cylinder to absorb the inertia
energy of the mechanical moving parts through
releasing its fluid and pressure. At the same time, an
emergency stop will pause the hoist moving as
long as the drive and PLC receives the signal sent
from the electrical overload transducer or the
pressure switches mounted on the snagged cylinders.
The total snag event takes place in less than a
second. Lowering the hoist is allowed at reduced
speed after first resetting control power to release
the strain on the ropes. No hoist raise motion is
permitted until the event is cleared.
7） Boom interlocks
Figure 1-6: Limit Switches at Drum End of If the boom is not fully at horizontal position
Main Hoist Drive (stowed or maintenance), the hoist motion is
1 Cam Switch 2 Over-speed Switch 3 Absolute Encoder disabled. When the boom is raised the hoist
functions at the reduced speed (empty spreader
only)
8） Spreader operation modes
The hoist and head-block / spreader system operates
in three different modes, container, cargo and reeve.
9） Spreader mode interlocks (Slack rope protection)
In case all the proximity switches around the twist
locks are activated (means cargo already landed),
further lowering motion of the spreader will be
inhibited. These switches contribute to preventing
Figure 1-7: Absolute Encoder the hoisting ropes from slacking. Hoisting motion is
2） Motor brake limit switch permitted when all these switches are released or
Each of the two hoist motor brakes is monitored by activated.
a brake released limit switch (one normally open
contact) and a brake manually-released limit switch
10）Spreader cable reel interlock
(for motorized cable reel only)
(one normally-closed contact). Without signal of
Whether improper tension, irrational position or
hoisting from joystick, the hoist motion is inhibited
selection of manual mode at the trolley top control
from operating as long as either switch is actuated.
station, the main hoist operation will be inhibited.
3） Drum brake limit switch The cable reel runs in two modes, auto and manual.
Each of the two hoist drum brakes is monitored by a Auto should be selected if operating from the cab
brake released limit switch (one normally open and manual selected if from the local control station
contact). Without hoisting signal from joystick, the settled on the trolley. Hoist movement, raise and
hoist motion is inhibited from operating as long as lower will be disable if the reel manual mode is
selected in both container mode and cargo mode.
6
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1.3.1.3 Positioning Limits for Main Hoist Drive
Normal hoist limits are controlled by the absolute

encoder mounted on the main hoist motor. The home (or
zero) position of the hoist is located at the upper limit of
normal travel, while the hoist height indication is still
counted from wharf ground level.
In addition to the absolute encoder limits, there is
another weight operated lever switch (as shown in Figure
1-8) mounted on the bottom of the trolley and a third cam
switch (as shown in Figure 1-6) installed on the hoist
drum end. Such redundant design provides the over travel
protection in a better and safer way. Figure 1-8: Trip Block under Trolley Frame
for the Weight Operated Lever Switch
As snag event occurs, the kinetic energy of the hoist

1.3.1.4 Trim-list-skew and snag protection device mechanism that is rotating at high speed is transformed
into heat energy and releases it by the hydraulic system,
These functions are accomplished by the which prevents the disaster such as wire rope broken,
multi-functional hydraulic system at girder end tie, which crane structure deforming or even whole crane
is composed of four hydraulic cylinders and valves overturning or collapsing.
power-pack. The hydraulic cylinders are attached to the The cylinder position is monitored by linear
four hoist ropes by turning sheaves. displacement transducers located inside each of the
The hoist rope provides spreader positioning cylinder rods. Output from each of the cylinders is
(trim/list/skew) and snag load protection through the directly proportional to the 1200mm stroke of the
multi-functional hydraulic system. cylinders. The initial home position, the minimum
extruding under working condition, is at least 750mm for
Spreader tilting is accomplished by manipulating the each of the cylinders. That is the stroke 0mm ~ 750mm
position of the cylinders, lengthening or shortening the for the snag protection, and stroke 750mm ~ 1200mm for
rope falls to adjust the container tipping angle around its the spreader Trim-List-Skew motions and/or
three orthogonal axes. compensating the length variety for the hoist wire ropes.
Figure 1-9 Spreader Trim-List-Skew and Snag Protection Device on the Girder Tie End
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1） Trim, list and skew motions  TRIM

By actuating combinations of hydraulic Tipping or rotating of the spreader around a
cylinders motions in different directions, this device horizontal axis perpendicular to the gantry rail.
adjusts the TRIM, the LIST and the SKEW. From the operator’s perspective, trim raises and
lowers the left or right end of the spreader as shown
in Figure 1-10.
Figure 1-10 Spreader Left Trim  and Right Trim 
 LIST Tipping or rotation of the spreader around an axis parallel to the gantry rails.
Figure 1-11 Spreader Forward List  and Backward List 
 SKEW Rotation of the spreader around a vertical axis.
Figure 1-12 Scheme of Spreader Clockwise Skew  and Counter Clockwise Skew 
When the Trim/List/Skew is at their maximum angles, the cylinders cannot actuate further. In such a case,
operate the respective HOME switch on the operator’s console to set it back to the HOME position.
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2） Snag Protecting Function must reset control power and lower the hoist to remove
the load (hoisting is not permitted). The crane is then to
Snag is a condition that typically occurs when a be inspected for damage before the SNAG RESET key
lifting spreader hooks or hits an obstruction such as the switch, located in the E Room is reset. Once reset full
cell guides or hatch combings in the ship’s cargo hold. crane functionality is permitted.
As snag occurs, the ropes’ tension will increase
rapidly and the hydraulic pressure of the snag cylinders 1.3.2 Boom hoist system
increases correspondingly. When the pressure of any one
of the four cylinders rises to the preset value of its 1.3.2.1 Boom hoist drive
pressure switch, a hardwired (fast) signal is sent directly
to the hoist drives that initiates an emergency stop to the The boom hoist drive is located in the machinery
hoist motors. At the same time, the relief valve will open house. It is powered by a variable frequency AC motor
to blow the fluid and the cylinders will retract. connected to the reducer input shafts through a flexible
elastomeric type coupling (high speed). A rope drum is
After the snag occurs, the snag indicating light will connected to the output shaft of the reducer through the
be on in the operator’s cab, an audible warning will be flexible gear coupling (lower speed). The driving force of
sounded and the control power will be shut off. this equipment is transmitted from the motor to the drum
Meanwhile, only lowering the hoist is allowed at the by the high speed coupling and drum coupling and
reduced speed to release the strain on the ropes and no amplified through the reducer driving the drum and rope
hoist raise motion is permitted. to raise or lower the boom. The data of main components
In order to exit the snag condition, first the operator as following:
Table 1-3: Main Data of Major Components for Boom Hoist Drive
Type 1LL8 315 Type SF24
Drum Brake Brake
Power 280kw 2X172.8kNm
Motor Torque
Rotating
1750rpm Type K260-560x30
speed
Rated
Type PD53-R11-V21-96.9 Motor Coupling 3.98kNm
Torque
Brake
Ratio 96.9 11.94kNm
Reducer Torque
Rated
Output 239kNm Type TTX26
Rated
Type SB28-560x30-121/6 390kNm
Torque
Motor Brake
Braking
3.55kNm Wire Rope Diameter Φ30mm
Torque
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8 Drum Brake 9 Bearing Seat and Limit Switch

Scheme and Photograph for Boom Hoist Drive
4 Reducer 5 Drum Coupling

2 Motor Brake 3 Motor Coupling
6 Rope Anti overlay Device 7 Drum

Figure 1-13
1 Motor
An emergency drive is located on the opposite side of main motor, its motor flanged onto the cycloidal
planetary pin wheel speed reducer. Upon failure of the boom hoist main motor or drive/control system
and can not be fixed immediately, this device can be used to raise or lower the boom at low speed. In case
the crane loss of high voltage power, it is also capable of slowly raising or lowering the boom by plugged
on shore power.
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1.3.2.2 Boom hoist rope reeving system

The hoisting or lowering of the boom can be altered
by changing the rotating direction of the motor. The
The wire rope pays out from the drum, then runs through
boom hoist drive lifts the boom to the 45º stowed position
the following route: Boom hoist drum → Sheave block
or to the 80º maintenance position through the reeving
on top of A-frame → Inner single sheave on the boom →
rope. The boom hoist reeving includes two independent
Sheave block on top of A-frame → Outer sheave blocks
and equalized sets of falls. Either of them can catch the
(4) on boom, rope runs 8 times to and fro between sheave
boom in the event of failure of one set. All sheaves
block on top of sheave and outer sheave block on boom
contained with bearings and through covers are designed
for either side reeving as shown in Figure 1-14.
as a unit when removed or installed.
Figure 1-14 Scheme of Boom Hoist Rope Reeving System
1 Outer Sheave Blocks On Boom 2 Inner Single Sheave on Boom 3 Sheave Blocks on Top of the A-Frame
4 Equalizer Sheave on Top of the A-Frame 5 Boom Hoist Drum
1.3.2.3 Boom hoist interlocks
1） Over-speed switch
As shown in Figure 1-15, the external over-speed
protection for the boom is provided at the end of the
drum. Actuation of switch initiates an emergency
stop. The theoretical trip speed setting for the switch
is 110% of the motor maximum speed. In order to
resume the crane operation, the switch must be
manually reset from its back once it is tripped.
(Refer to Figure 1-15) As an optional device, which
is connected with the motor shaft end, the
incremental encoder can transmit the real-time
speed signal then PLC will evaluate over-speed or
not. Figure 1-15 Limit Switches at Drum Shaft end
1 Cam Switch 2 Over-speed Switch 3 Absolute Encoder

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2） Motor brake limit switch switches is actuated.
The motor brake is monitored by a brake released
limit switch (one normally open contact) and a
brake manually released limit switch (one normally
closed contact). Under no command of boom up or
down, the boom motion is inhibited from operating
as long as either switch is activated.
3） Drum brake limit switches
Two boom drum brakes are monitored by a brake
released limit switch (one normally open contact).
Under no command of boom up or down, the boom
motion is inhibited from operating as long as either
switch is activated.
4） Motor thermal switch
The motor features an embedded over-temperature
switch (one normally closed contact). Actuation of
the switch indicates the motor temperature is at fault
level and the boom motion is inhibited. Figure 1-17 Rope slack switch
5） Trolley park position check
The trolley park position is monitored by a
magnet-operated proximity switch. The boom 1.3.2.4 Boom traveling limits
motion is inhibited from operating as long as the
trolley is not indicated to be in the park position. Normal boom hoist limits are controlled by the
6） Boom stowage pin stored in storage socket check absolute encoder mounted on the drum shaft end. The
The boom stow pins are monitored by proximity home position of the boom hoist is set by lowering the
switches(As shown in Figure 1-16). Actuation of the boom to down stop position.
switch indicates that the stow pin is rested in the In addition to the absolute encoder limits, there is a
storage socket and boom motion is permissive. lever operated limit switch mounted on the top of
Boom motion is inhibited from operation as long as A-frame (As shown in Figure 1-18) and a multi-cam
either of switches is deactivated. rotary limit switch mounted on the end of boom drum (As
shown in Figure 1-15). This redundant design provides
Limit switch
the over travel protection in a better way.
Limit switch Limit switch
Figure 1-16 Proximate switch for checking

stow pin in storage socket Figure 1-18 Mechanical Limit switches for
Boom stowage
7） Rope slack protection
The boom ropes are monitored by two lever
operated limit switches, one for each of the rope
falls. The boom motion is inhibited from operation
(only lowering direction) as long as either of the
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During the process of boom raising up, a spotter must stand on the seaside upper beams, carefully observe the
whole process. The spotter must keep good communication with the operator. Once found anything abnormal,
the operation should be stopped. In cases of emergency, immediately press the emergency stop switch. Before
the recovery boom up operation, make a thorough check to ensure that the fault has been eliminated.
1.3.3 Trolley travel system

flexible gear coupling (lower speed). The driving force of
1.3.3.1 Trolley travel drive this equipment is transmitted from the motor to the drum
by the high speed coupling and drum coupling amplified
The trolley travel drive is located in the machinery through the reducer driving the drum and rope to propel
house. It is powered by a variable frequency AC motor the trolley forward (seaside) or backward (landside). The
connected to the reducer input shaft through a flexible data of main components refers to Table 1-4.
elastomeric type coupling (high speed). A rope drum is
connected to the output shaft of the reducer through the
Table 1-4: Main Data of Major Components for Trolley Travel Drive
Type 1LL831-4 Type Without equipment
Drum Brake
Motor Power 270kw Brake Torque
Rotating speed 1750rpm Type K260-560x30
Type PD40-R11-V24-19,7 Motor Coupling Rated Torque 3.98kNm
Ratio 19.7 Brake Torque 11.94kNm
Reducer
Rated Output
79KNm Type TTX6
Type SB28-560X30-80/7bb Rated Torque 110kNm
Motor Brake
Braking Torque 3.07kNm Wire Rope Diameter Φ22mm
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Figure 1-19 Scheme and Photograph for Trolley Travel Drive
5 Motor Brake 6 Motor Coupling 7 Drum Coupling 8 Reducer

1 Encoder 2 Bearing Seat 3 Drum 4 Motor
The trolley travel drive is equipped with an emergency drive. The device is capable of moving the trolley
slowly forward or backward powered by the shore power in case the trolley motor or drive control
system failed and can not be fixed immediately.
to the following rounte:

1.3.3.2Trolley rope reeving system
Drum→Boom tip sheaves assembly→Trolley→Boom
By wire rope, drum, trolley, tensioning device and a tip sheaves assembly→Drum，Drum→Sheave of rope
series of related components linked together to form a tensioning device at girder rear section→Trolley→
trolley rope reeving system. Sheave of rope tensioning device at girder rear section
Two wire rope, four ends, clamp the rope on the drum →Drum（As shown in Figure 1-20）；The trolley run
firmly(see the main trolley drive device), and the back and forth by driving device.
midpoint of wire rope is fixed on the trolley, according
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Figure 1-20 Trolley Rope Reeving System

1 Boom tip sheave assembly 2 Dead end connection at trolley
3 Trolley drum 4 Sheave of rope tensioning device at girder rear section
1.3.3.3Trolley interlocks limits 1.3.3.4 Trolley traveling limits
1） Motor brake limit switch 1） Waterside over travel stop

The brake is monitored by a brake released limit Controlled by Lever operated limit switch together
switch (one normally open contact) and a brake with the absolute encoder mounted on trolley drum
manually released limit switch (one normally closed shaft end, actuation any of these limit initiates an
contact). Under no trolley command from joystick, emergency stop to boom hoist motor. The “limit
the trolley motion is inhibited from operating as back-out bypass” selector switch in the electrical
long as the switch is activated. house permits trolley traveling towards landside.
2） Motor thermal switch 2） Waterside normal end stop
The trolley motor features an embedded Controlled by proximate limit switch together with
over-temperature switch (one normally closed the absolute encoder, actuation of this normal
contact). Actuation of the switch indicates the motor working end stop initiates a ramp stop.
temperature is at fault level and initiates a ramp stop.
The trolley motion is inhibited from operating as 3） Waterside slowdown check
long as the switch is opened. Controlled by magnetic inductive limit switch together
with the absolute encoder attached on the motor end
3） Boom hoist interlocks shaft, actuation of the proximate switch and trolley
If the boom is not at right position (not fully speed verified not slowdown to set range by the
lowered to level or fully up to stop position), the encoder will initiate an emergency stop.(As shown in
trolley motion will be disabled Figure1-21)
4） Cab access gate

Each of the two gates to the trolley, one on the
portal frame and the other located on the trolley, is
monitored by a gate closed proximity switch.
Actuation of either of the switches indicates the
respective gate is not closed well the trolley motion
is to be inhibited.
5） Trolley rope tensioning limit switches
This protection consists of four proximity switches,
two for each utmost stroke of the rope tensioning
cylinders. The trolley motion is inhibited from Figure 1-21:Roller Lever Operated and Magnetic
operation as long as either of them is activated. Inductive Limit Switches around Boom Forward
End.
4） Waterside smart slowdown
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Under the control of the absolute encoder together 10） Landside slowdown check
with PLC software limit, the speed could be set in This is similar to the waterside slowdown check.
real-time way and slowdown to the setting value
right within the slowdown distance in order to ease 11） Landside normal end stop
the tiredness caused by sudden stop. This is similar to the waterside normal end stop.
5） Trolley Encoder Reset 12） Landside over travel stop

Actuation of the proximate switch initiates resetting This is similar to the waterside over travel stop.
a new position value for the absolute encoder.
1.3.3.5Trolley travel rope tensioner
6） Waterside normal end stop (boom stow position)
Actuation anyone of the proximate switch together Trolley rope tensioners are located at the rear of the
with absolute encoder indicates a ramp stop for the girder and apply appropriate tension to the trolley travel
trolley(As shown in Figure 1-22). ropes by actuating two hydraulic cylinders attached to
trolley sheave through the sheave arm. With this function,
surging of the trolley due to the loosening of the wire
rope during loading or unloading of the container will be
minimized(As shown in Figure 1-24).
Figure 1-22 Magnetic Inductive Limit Switches

nearby Boom Heel end.
Figure 1-24 Trolley Travel Rope Tensioner
7） Park position
Controlled by proximity switch together with the The cylinders are powered by the multi-function
absolute encoder, actuation of this limit switches power unit with pre-set pressures to the hydraulic
indicates trolley at park position and permits boom cylinders. The rope tensioning cylinders will retract to
motions(As shown in Figure 1-23). prevent the ropes from over-tensioning due to the
changes of the waterside rope length as the boom rises.
The cylinders will extend to keep the ropes under proper
tensioning due to new ropes stretch after a period of
operation.
In many cases, the wire rope length needs

adjustment due to the stretching and
slackening of the wire rope, and this
variation is difficult to notice especially in
continuous catenary roller support
system.
The position of the cylinder is monitored by two

Figure1-23: Trolley Parking Position Limit proximity switches and actual position is decided by the
Switch real presetting pressure / tension force. The desired
8） Sill beam protection position of the cylinder is that the sheave arm is almost
Under the control of the absolute encoder, actuation vertical under the pressure of hydraulic system. The arm
of any sill beam stop initiates a ramp stop in order may offset from its original position and trolley motion is
that the spreader safely crosses over the sill beam. allowed until either of limit switches is activated. If limit
switch tripped and cylinders in normal pressure wire rope
9） Landside smart slowdown length needs to be adjusted.
This is similar to the waterside smart slowdown.
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1.3.3.6Trolley Trolley clips
The function of trolley is carrying spreader and

container back and forth, in order to achieve the
handling of containers. The movement of the car is
achieved through the wire rope. As shown in Figure
1-25、1-26、1-27.
Figure 1-26 Rope Clamp with Adjustable

Screw Rod
Figure 1-25 Rope Guide Rollers on Trolley
Frame Four traveling wheels are on the trolley frame
corners. The wheels have anti-friction bearings with split
pillow blocks for easy removal. The main hoist rope
sheaves are mounted on the trolley frame. They
accomplish the rope pickup and diverting.
The trolley frame has four pneumatic-hydraulic
buffers at the seaside and the landside to minimize the
impact on the end stop in case of an electrical control
failure.
Figure 1-27 Trolley Assembly Photograph
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A seat with safety belts and shoulder harness,
1.3.3.7Operator’s cab
adjustable to accommodate a person’s weight, height and
distance from the front windows, is positioned so that the
The cab is purposefully and ergonomically designed
operator can reach all control switches comfortably.
to serve the crane operator. Attention was focused on
providing comfort and convenience so that the operators All master switches, indicating lights, selector switches,
can concentrate on the serious task of handling containers, joy sticks, and other control devices have been conveniently
and not be distracted or encumbered by uncomfortable arranged on the left and right consoles, the auxiliary panel,
surroundings. twist lock indicating panel along the foot rest, and on the
three computer and TV monitors, so the operator can access
All primary crane functions can be achieved in the any of them without leaving your chair(As shown in Figure
cab. The cab is mounted to the trolley framework on its 1-28&Figure 1-29).
landside to provide the best possible view during loading
or unloading operation. 1.3.4 Gantry
1.3.4.1 Gantry travel drive
Gantry traveling devices drive the crane travel along

the runway. Half wheels on each corner are driving
wheels. Each drive device applies a an AC inverter motor
driving a wheel. Speed coordination between the two
motions is controlled through a pulse tachometer
mounted on each far left motor. To prevent the crane from
shifting in storm wind (stowed wind), two sets of stowage
pins are provided under the seaside and landside sill
beams. In addition to motor mounted brakes which brake
the driven wheels, hydraulic wheel brakes are mounted at
each idler wheel to prevent the crane from moving in
Figure 1-28 Operator’s Cab Appearance wind gusts during the operation(As shown in Figure
1-30&Figure 1-31).
The driving force from the motor is transmitted
through the gear coupling and gear reducer to the drive
wheel. Travel direction of the gantry can be altered by
changing the rotating direction of the motor. A thruster
disc brake for each drive unit is provided between the
motor and gearbox. The motor brakes are sufficient to
stop the gantry. In addition to the motor brake, a wheel
brake for each idler wheel is provided. The motor brakes
combined with the rail brakes are sufficient to hold the
crane at the wind speed 45m/sec. But if the forecasted
wind speed is over 45m/sec, the stowage pin and tie
down are required to be engaged in proper way. The data
of main components refers to Table 1-5.
Figure 1-29 In View from Floor Window in

Operator’s Cab
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Table 1-5: Main Data of Major Components for Gantry Travel Drive
Type 1LP4-186-4CA91-Z Type RBHS-DT-200-050
Rail Brake
Power 20kw Clamping Force 222KN
Motor
Rotating speed 1400rpm Type ML5
Motor Coupling
Braking Torque 250Nm Rated Torque 400Nm
Type TNR430.96.D2A.00 Type 23MFZ140-17
Reducer Max Permissible
Ratio 95.954 Buffer 700KN
Impact force
Motor Type See motor Stroke 400mm
Brake Braking Torque 250Nm Wheel Diameter Φ800mm
Figure 1-30: Landside Gantry Full View
1 Buffer 4 Motor Brake

3 Motor 5 Gear Reducer
2 Motor Coupling 6 Gantry Wheel
Figure 0-31: Scheme & Photography of Gantry Drive Unit
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1.3.4.2 Interlocks for Gantry Drive 1.3.4.3 Gantry Maintenance Cab
1） Motor brake limit switches There is a gantry maintenance cab installed in the
Each one of the 16 motor brakes is monitored by a Anchor & checker's cabin under the landside sill beam.
proximate limit switch. The cab is provided with electric lock. Only those who
have the mechanical key or the electronic key can access
2） Gantry rail brake released check limit switches this cab. A ground control station and CMS terminal are
Each one of the 4 rail brakes is monitored by a mounted in this cab. This control station will help to
proximate limit switch provided by Hillmar. maintain the spreader and stow the crane.
3） Gantry stow pins All functions of the spreader can be achieved on this
Each of the two stow pins on gantry, in both landside station. The main hoist can be operated with empty
and waterside, is monitored and checked whether in spreader only(As shown in Figure 1-33).
released position by a proximity switch. As long as
either pin is not in the retracted position, the gantry
motion is inhibited from operating.
4） Gantry buffer limit switch & gantry slowdown
scanner
Each of the two gantry buffers located at waterside is
monitored by a proximity switch. The gantry motion
is inhibited from operating and a warning sounded as
long as either side buffer is compressed to setting
position.
gantry buffer
limit switch
Figure 1-33: Gantry Maintenance Cab
gantry slowdown
scanner
Gantry Buffer Limit Switches& Gantry Slowdown

Scanner
5） Motor encoder
The gantry motor frequency varying as well the speed
are monitored and controlled by a pulse Tachometer
which is attached on the motor end shaft.
6） Anemometer (wind speed) system
Wind speed and direction monitoring for the gantry
drive is provided by anemometer system. The
anemometer transducer located on top of the A-frame,
for measuring the wind speed and direction, a control
module located in the electrical room, and an digital
meter located in the operator’s cab for displaying
wind speed.
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Each crane’s anchoring device are installed at the
1.4 Crane safety facilities centerline under the landside sill beam and seaside sill
beam. Anchor plate of the anchor device can be lifted up
1.4.1 Crane Stowage Device and Tie-Down Device or down by operating the handle. Lift anchor plate by a
pin lock to guarantee not to interfere with the wharf
It is important and necessary to properly stow the surface of quayside walk properly; anchor plate down to
crane safely on the designated site of dock (stowage and insert embedded parts of the pier pit, to resist wind force
tie down pit). If not stowed, there will be a danger in the along the rail(As shown in Figure 1-35).
event of a sudden high wind condition. The motor brake
and wheel brake can only guarantee locking the wheel
with no rotation but can not prevent the crane from No operation is allowed when wind
sliding along the rail. Once in motion, a crane can exceeds 19.4m/sec! Crane must be
develop momentum and strike another crane or other stowed at its stowage position. Crane
obstacle and cause serious damage(As shown in Figure must be secured in tie-down condition
1-34). when wind exceeds 40.2m/sec.
Anchor pin
Anchor hole
Figure1-34: Anchor Device
Figure1-35: Gantry Rail Brake Located under Equalizer Beam centered
1.4.2Boom stowage device

This device is for securing the boom when the boom The boom motion will ramp stop when the normal
rises to the maintenance position (80°). It consists of two stop limit switch is activated. At that time, the latch hole
sets of pins and sockets, as shown in Figure 1-36. The on the boom is aligned with that on the stowage device.
pins are stored in the storage sockets under normal Pull pins out of the storage sockets and insert them into
operation. The boom motion is inhibited from operation the latch hole. Insertion of an anchor pins must be done
as long as either of the pins is not inside the storage by manpower.
sockets for safety.
When trying to lower the boom, the pins must be
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inserted back into the storage sockets. Otherwise there is the pins.
no motion of the boom. There are limit switches to sense
Stowage
Pin Hole
Stowage Pin Storage Socket
Engaged in Storage Socket  Disengaged 

Figure 0-36: Boom Stowage Pin Stored
1.4.3 Ship collision protection and top of A-frame is equipped with an obstruction
light to flash at night for warning the flying objects
A stainless steel trip wire runs down each side of the avoiding.
boom to protect the lowest surface of the boom from
contacting the ship structure. A LMS sick scanner switch
is located on both sides of the boom. If either limit switch
is activated, further travel toward ship will be inhibited
and a warning signal will be sounded through the public
address (PA) system. But the crane can only move away
from the ship until the limit switch is de-activated. A
bypass switch in the cab allows the gantry to travel in the
detected direction. In this bypass mode, the warning light
and the horn will activate.
Figure 1-38: Obstruction Light
1.5 Auxiliary equipments on crane
1.5.1 Power cable reel

A cable reel device rides on the frame link beam to
delivery the high voltage power for the crane. As crane
traveling, the cable is wound or paid out by the cable reel,
which is driven by the gearbox output torque transmitted
from the motor through a magnetic hysteresis coupling. A
Figure 1-37: Ship Anti-collision Device guide roller device above the ground helps to lay the
cable in a pit or pick up from it. On the opposite side of
1.4.4 Obstruction lights gearbox, a high voltage slip rings connected with the
output shaft feeds H.V power to the crane(As shown in
Each location of boom tip, trolley girder rear end
Figure 1-39).
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1.6.2 Service crane outdoors
Type of service cranes are provided outdoors on this
crane, jib crane. One jib cranes located on the top of
A-frame serve for replacing sheaves. Another on the
girder, service crane is supplied to take care of the
cylinders, sheaves on rear tie beam as well as the sheaves
and wheels on trolley. Some handling tools such as plain
trolley and chain blocks need to be put on temporarily
while moving components during maintenance(As shown
in Figure 1-41&Figure 1-42).
Figure 1-39: Power Cable Reel System
1.5.2 Trolley festoon system

This project applies Wampfler chain assembly,
please refer to Wampfler maintenance manual for
detail.
1.6 Maintenance equipment

The maintenance equipments provided on the crane Figure 1-41: Jib Crane on the Top of A-frame
includes service crane inside machinery house, rope
re-reeving device, service platform and tool kit, etc.
1.6.1 Machinery house service crane

A service crane with 8 tons rated capability is
provided in the machinery house(As shown in Figure 1-40).
Three motions of hoisting, transverse crossing and
longitudinal traveling can cover the whole house. The
service crane spans the machinery house and is capable
of centering over, lifting and traveling with any
component inside the machinery house as well as
carrying components between the machinery house and
wharf level. In order to position parts accurately, it is
furnished with two stage hoisting speeds, one for fast and
Figure 1-42: Jib Crane on Girder End
one for slow.
1.6.3Wire Rope Re-reeving Device
A re-reeving device is mounted over the main hoist
drive in the machinery house(As shown in Figure 1-43). It
consists of two cable drums including a motorized one
equipped with brake device. During re-reeving procedure,
the device winds the old rope on its take-up reel tightly
and the new wire rope is on the feeder reel. For detailed
rope re-reeving procedure, please refer to Chapter 4 of
this manual.
Figure 1-40: Service Crane in Machinery House

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1.7Walkways, access and elevator
1.7.1Walkways and Platform

Each crane access to every part of the crane needing
routine inspection or maintenance is provided with
stairways, walkways, and ladders. The main access
stairway is located on the landside left leg. Rest platforms
are provided at various elevations along the stairways
which can be used to access the portal tie beam,
operator’s cab parking position, or machinery house
elevation(As shown in Figure 1-44 ; Figure 1-45 ; Figure
1-46 & Figure 1-47).
Figure 1-43: Re-Reeving Device Mounted Over

the Main Hoist Drive
Figure 1-44: Side View of Access General Arrangement
Figure 1-45: Top View of Access General Arrangement
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Figure 1-46: Maintenance Platform for Festoon System Figure 1-473: Maintenance Platform for Boom
Forestays
1.7.2Elevator
On the same leg which the main access located at
(crane stairway access), a man-carried elevator is
installed for up and down. The main data of the elevator
refers to Table 1-6 below.. For detailed maintenance
instruction, please refer to an independent manual of
Shen Yang .(As shown in Figure 1-48;Figure 1-49).
.
Table 1-6: Main Data for Elevator
Rated Capacity 400kg/4persons Care Size (inside) 1000x1000x2150
Type SC40 Car Floor Area ~0.5m square meter
Voltage 440V 1st Landing Elevation 5.7m Landside Ladder Access
Frequency 60Hz 2nd Landing Elevation 15.03m Access to the Portal Tie Beam
Rated Speed 0.6m/s 3rd Landing Elevation 45.153m Access to the Operator’s Cabin
Motor Power 12.7Kw 4th Landing Elevation 50.53m Access to the Machinery House
Figure 1-48: Elevator Figure 1-49: Elevator Car
25
`
furnished with pins (twist locks or horizontal pins) for
1.8 Handling system connecting to the spreader or the cargo beam. The
engagement or disengagement of the pins is monitored by
1.8.1 Spreader proximity switches (As shown in Figure 1-51).
As a “hand” of the crane, the spreader is the
executive part of the crane to handle the containers. The
spreader is designed to lift two 20’ containers separated to
1.6 meter, with 51 tons capacity in single 40’ mode and
65 (2x32.5) tons in twin operation(As shown in Figure
1-50).
Figure 1-51: Headblock.
1.8.3 Cargo beam

The Cargo beam of 80 tons rated capacity is
designed to handle non-containerized loads (As shown in
Figure 1-52).
Figure 1-50: Spreader
1.8.2 Headblock
Figure 1-52: Cargo Beam
Four hoist sheaves mounted on the each corner of
the headblock frame are the links between the hoist rope
reeving system and the spreader and permanently reeved
into the crane. It is a structural part of the crane and
designed for specified crane capacity. The head block is
26
Industries Co.,Ltd. Chapter two
Chapter 2 Crane maintenance instructions

2.1 General section should be read thoroughly and carefully in order to
get clear general ideas on maintenance safety and
Crane Maintenance is composed of Inspection, instructions. Safety is always a first priority in any
Routine Maintenance and Repair。This Chapter basically maintenance operation. When a crane is under
expands upon the operating maintenance and routine maintenance, some of its parts may be disassembled or
inspection of the crane. unstable, thus special attention should be paid. Operators
and maintenance personnel should be familiar with the
The inspection and routine maintenance is used to check crane’s features. Before operating or maintaining the crane,
whether the crane is in a safe state and to place the crane maintenance and operation instructions have to be read
into a condition where a high confidence of reliable carefully and understood by all maintenance and repair
operation can be developed. The main work of the personnel. The crane should be put into operation only by
inspection and routine maintenance includes cleanliness, authorized and trained specialists. Follow local safety laws
lubrication, fasteners and connections, spot-check and and codes issued by the related authorities (i.e. Cal/OSHA,
periodic inspection. City of Long Beach, Pacific Coast Marine Safety Code,
PCMSC, and others applicable). Safety requirements
It is basically a visual inspection and some mentioned in this manual, as well as special safety
functional/detective tests. If, in doing so, an adequate cautions on the maintenance tasks are all valid.
assessment is not possible, a disassembly of crane parts
has to be undertaken to get access to the hidden parts. Always read this manual thoroughly
Chapter 3 “The repair Instructions” will illustrate crane before operating, inspecting and
repair procedures in detail on components which need maintaining the cranes. Before
disassembly and disengagement. commencement of service work, the
container crane must always be made
The cautions and instructions about inspection and free of load, set to maintenance position
maintenance are outlined, aiming at giving a general idea and in a LOCKOUT/TAGOUT condition
on how to carry out an inspection and a routine on effected systems if no other note is
maintenance. given.
Inspection of cleanliness
Refrain from any working method that
Inspection of fasteners and connections may inhibit safety!
Inspection of concentricity (alignment) periodically

Danger of falling!
Inspection of lubrication
Inspection and preventive actions Danger of tripping!

In addition to this maintenance manual, all
subcontractors have manuals for their own components. To
maintain such components, please refer to their manuals. Keep hands and body clear of moving or
The list of these manuals is in Table 2-1 as follows. rotating parts!
2.2 Cautions and safety notes

Wear protective clothing!
Fo r re pa iri ng pa rt s o r re pla ci ng
co mp o n en t s sa f e ly, ma i nt e na nce
per so n s mu st f o llo w t he Hazardous voltage!
de scr i pt io n i n t h i s ma n ua l a n d
ma n ua ls it ha s me nt io n ed. T he
re lev a nt s ect io n s o f t hi s ma n ua l Keep away from suspended loads!
a re t o be st u d ie d ca ref ul ly bef o re
ev ery ma i nt e na nc e o r repa ir.
Before starting any maintenance or repair job, this

The following are the safety instructions in maintenance:
2- 1
2.2.1 Safety rules of operation spotter between the operator and the mechanic
while inspecting the rope.
1) Follow the safety laws and codes issued by 4) When handling parts from the hatches on the
local government. Safety requirements floor in the machinery house, install protection
mentioned by the user, manufacturer and around the hatch with its fenders before
fittings supplier of auxiliary materials are all opening it.
valid. 5) Conductive parts must be switched off and
2) Only qualified, trained, and designated secured against reactivation.
personnel may carry out the repairs and 6) Provide absorbing devices for leaking
maintenance on the crane. operating materials.
3) The crane should be set to maintenance mode 7) Wear protective clothing(oil and
and safety methods should be adopted for such petrol-resistant gloves, protective clothing, eye
tasks. goggle, helmet, protective footwear)
4) Use safety harnesses and other safety gears as 8) Handle operating and cleaning detergents and
needed when working where you do not have a solvents cautiously.
safe working platform and handrails to protect 9) Provide a safe and environmentally friendly
you. It is a good practice to work as a team of release, storage and disposal of operating and
at least two persons when engaging in auxiliary materials.
maintenance and repair work where there is 10) Do not use machine parts as climbing aids.
potential danger. 11) Reinstall and test safety devices (which have
5) Where inspections or work is being performed been disassembled during maintenance or test
during the mechanism motion or rotation, and repair work) immediately after the end of
enough spotters must be present watching each maintenance and repair work.
worker and ready to depress an Emergency 12) Inform the operating personnel before the
Stop. Radios should be used to maintain commencement of special or maintenance
communications with the operator. When a work.
person stands on the trolley during 13) Tighten screw joints which were loosened
maintenance, he must wear safety harness, and during test and maintenance work correctly.
install safety chains near the rope inspection 14) Replace fastening elements and seals (e.g.
platform. When the trolley requires moving self-securing nuts, washers, split pins, O-rings
during the maintenance or inspection, even at a and seals) which cannot be used again.
very slow speed, the person on the trolley must
stay within designated platforms/hand-railing 2.2.3 Safety Rules after Maintenance / Repair Work
and pay special attention to any potential crush
hazard. 1) Update fault log and maintenance check list.
6) Secure the repair area by closing a wider area The responsible maintenance personnel must
and set striking signs and symbols about safety make also assure that the occurred faults are
warning to prevent other idle person from logged and eliminated.
entering. 2) Put away tools, foreign parts and operating
7) During maintenance on the crane, be sure to materials left lying around.
close hatches on the machinery house and 3) The cranes have been provided with non-slip
other places, or to protect them with fences. grating walking surfaces where possible. Many
Where inspections or work is being performed of these walking surfaces are more than 40m
without designated platforms/hand-railing, high at the cab and machinery house elevation.
safety harness and other safety equipment An object, which falls from such a height to
should be used. the ground, is traveling at high speeds that can
cause serious injury or even death if it strikes a
2.2.2 Safety Rules During repairing or maintenance person on the ground. It is everyone’s duty and
responsibility to pick up any object or debris
1) If hands will be on rope for inspection, found on the crane to avoid accidents.
lubrication or for any reason, they must be rope 4) Test running and functional check of the
traveling away from pinch point. components and safety devices. A functional
2) The maintenance persons should pay particular test has to be carried out before starting
attention to the moving/rotating parts. operation and service again.
3) An additional person is needed to act as a
2- 2
application including: cleanness of the faying

2.3 Cleanliness face of the precision components such as
bearing and deadeye, and wiping off dust from
The dust, oil dirt, water, impurity interfusing into the the surface of complicated shape part, electric
lubricant, rust and etc. may erode, speedup abrasion and element and other elements.
depress even destroy partial original performance like
reduce the braking moment, bring the electrical system 3) Cleaning by machining：
short circuit or other malfunction, infect the leak-proofness
of the hydraulic system and even destroy the hydraulic a. Use wire brush or electric polisher with
parts and bring severe result like system malfunction. copper brush. This method can remove the
Cleanliness is not only to keep a friendly environment but flotation rust or metal surface treatment
also to keep the machine super performance and prolong before repairing paint.
its lifetime. So in the routine maintenance the impassive
contamination to the parts and equipments should be b. Cleanness by finish machining such as
timely removed and keep the equipment leak tightness, turning or grinding. This method only is
without dust and oil dirt. The following are the routine adopted in renovating the defective surface
methods and typical examples to keep the crane clean. such as bulge or sunken in the brake disc,
brake lining and so on.
2.3.1 Major methods of cleanliness
2.3.1.2 Using cleanser
2.3.1.1 Dry cleaning
The cleanser is needed when the oil dirt on the
“Dry cleaning” used here means adopting physical surface is difficult to remove. In choosing the cleanser,
methods to remove the contamination from the surface advert to the problem that the solvent or cleanser based on
without water or solvent. Shown in figure 2-1, the main halogenated hydrocarbon like trichloroethylene and
methods including: dichloromethane will bring chemical reaction (injecting
little water into the trichloroethylene, hydrochloric acid
1) The cleaner can directly remove the dust and will generate) with the aluminum part, austenitic steel and
small dirt from the body surface. To create a galvanized part, and the part will be oxygenized. On
clean environment and improve the service life extreme condition, such reaction will bring explosion. So
and stability of equipment, the place where the solvent or cleanser based on halogenated hydrocarbon
mechanical and electric equipments concentrate shouldn’t be used when cleaning the metal parts of the
like machinery house, electric house and cab crane. In addition, the acid and alkali liquor shouldn’t be
should be cleaned periodly. used to clean the mental parts of the crane either, or it will
destroy the parts directly. To cope with the common dirt,
2) Air compressor and air blower can directly such cleanser as general gasoline bought in the market and
remove the powder, iron chipping and other industrial benzene can be used. As for the dogged dirt, use
waste falling off from body surface easily. Its the cleanser such as dimethyl benzene.
Industry Cleaner Air Compressor and Air Blower Wire Brush、Copper Brush and Corner Grinder
Figure 2-1：Routine dry cleaning method
Attention: Necessary protective equipments such as the goggles, gauntlet and costume should be worn
to prohibit hurting to the body by powder, scrap iron and even the cold wind.
Attention: Some cleansers such as methylbenzene, dimethyle benzene, acetone, and trichloroethylene
are poisonous. The related instruction book should be read carefully before using it.
2- 3
sides of rail should be clean。

2.3.2 Main cleaning work
5) The gantry running rail surface as well as both
The following are some typical examples of sides of rail should be clean, and no foreign
cleanliness： matter is permitted.
2.3.2.1 Cleanliness of common parts 6) The elevator guiding rail should be clean. No
foreign matter is permitted.
1) Braking disc (braking wheel) and the brake
lining (braking shoe) must be kept clean on the 7) The position easy to be corroded by seawater
surface at all times. No oil dirt, dust and rust, should be cleaned periodically.
convex block, burr and painting coat will be
8) All glass in the operator’s cab, main control
permitted. Every rotating pin shaft of brake
room and boom control room should be
should be kept clean and free in rotation. No
cleaned frequently to ensure a good view for
paint contamination and rust will be permitted
the operators (as Figure 2-4).
(shown as Figure 2-2).
9) Indication lights should be cleaned if there are
powder dust and other contamination to ensure
that the operators and maintenance personnel
can identify colorful lights clearly.
10) All rear mirrors should be kept clean.
Figure 2-2：Oil dirt and rust on the brake disc

must be removed
2) The cooling fan filter of the motor should be

kept clean and properly ventilated (shown as
Figure 2-3). As to the DC motor, the
commutator should be kept clean.
Figure 2-4： Operator’s cab
11) Remove excess grease and oil resulting from

lubrication of the crane components, both as
part of the lubricating activity and following a
short period of operation.
12) The parts should be cleaned before

reassembling.
2.3.2.2 Cleanliness of the electric elements and

system
1) Powder dust should be cleaned periodically for

the high-voltage transformer to avoid leakage.
Figure 2-3：Fan and fan filter 2) The electric control room should be kept clean.
Doors and windows should be closed, and
3) The internal of gear reducers should be kept powder dust inside control panels and other
clean. The bottom of the housing must be places should be cleaned by vacuum cleaner.
cleaned when oil is replaced. Pressure fan should be operated at all times.
4) The trolley running rail surface as well as both 3) Using dust collector to clean the place easy to
2- 4
sorb dust like the controlling panels and that of the system, the oil temperature should
computer screens in the electric and CMS be kept between 45 ～ 80℃. In order to
house (as Figure 2-5). completely remove the impurity in the system,
keep cleaning oil flow in large capacity.
Hydraulic system should be cleaned over three
times and after each cleaning the cleaning oil
used should be sent out completely before it
cool down. Before fill new oil, the filter
should be cleaned and new filter element
should be adopted.
B. Keep the air out of the hydraulic system

The entrained air in the hydraulics will cause
elements cavitation erosion, make the compressibility
increased and the operation instability, reduce the work
efficiency and make the actuator “crawl”. In addition, the
air will also make the oil oxidation and speeding up its
Figure 2-5：PLC controlling panel metamorphism. To keep the air out of the hydraulics the
following list should be paid attention to:
2.3.2.3 Cleanliness of the hydraulic system
1) Random check should be conducted after
Clean oil is the life of the hydraulic system. If maintenance and changing oil, and then begin
impurity trespass the small damping holes or the gap in normal work. As shown in the Figure 2-6 is the
the precision component, the component will be pulled exhaust valve of the snag –protection
damaged and the oil roads will be jammed, which will cylinder used in the girder.
bring danger to the safety running of the hydraulic system.
Generally the impurity inbreak methods include: unclean
hydraulic oil, unclean oil filling tools, carelessness in
filling oil and maintenance, impurity slipping from Exhaust valve
hydraulic elements and air or water entered into the
hydraulic system.
A. The way to prohibit the impurity from inbreak

1) Before fill oil, the hydraulic oil should be
filtered, the oil filling tools should be clean and
the filter placed at the entry of the oil tank
should not to be removed in order to speed up
filling. To prohibit the solid or fibre impurity
from inbreak, the oiler should keep the glove
and clothing clean. Figure 2-6：Exhaust valve of the snag
2) In maintenance when the oil filling cover, the –protection cylinder used in the girder.
filter cover, inspecting holes or the oil pipe is 2) The mouth of the inlet pipe in the pump can
taken down, keep way from the flying dust. not come out of the oil lever and keep the inlet
The cover of the oil tank can not be opened pipe being well sealed.
until the dirt around the tank cover has been
removed and the impurity at the connection 3) To keep well obturation for the driving axis of
place has also been removed after loosing the the lubropump, oil seal certified commended
bolts (to refrain the water from infiltration, the by the supplier should be adopted and ensure
water can not be used to clean the impurity). the function of airproof and oil proofing
Choose the cleaning materials without fibre
impurity dropping off and hammer with rubber C. Prevent water penetration into hydraulics
beating surface if they have to be used.
Hydraulic elements and hoses should be If the oil contains excessive water, that will make
cleaned and blow dry before assembling. The the hydraulic elements corroded, the oil emulsified and
filter also should be cleaned when oil changes. metamorphosed, the tenacity of lubricating film reduced
and abrasion speedup up. If the water in the oil is super
3) The type of cleaning oil should be the same as standard, the hydraulics needs to be clean thoroughly and
2- 5
the oil should to be replaced.
D. Inspection of the filter element

Filter is the cleaning equipment used in the
hydraulic system. As shown in Figure 2-7 is the filter of
the hydraulic power package located on the girder.
Inspect the squalidity degree of the filter and the
characters of the impurity on the filter element to provide
evidence for further fault diagnosis.
Figure 2-7：Filter of the hydraulic power

package located on the girder
2- 6
2.4 Fastening Grade 8.8 Grade 5 8 Grade 5

Grade 9.8 9
2.4.1 Grade of fasteners Grade 10.9 Grade 8 10 Grade 8
Although all bolts used on the crane are based on Fasteners used for metal structures should be ISO
Chinese standard, the Chinese standard for bolts is same Grade 8.8 and 10.9 (ASTM A325 or ASTM A490)
as the ISO standard. The bolts are also equal to the high-strength bolts. The bolt head and nut are usually
American metric bolts in specification and have bigger than the common ones and the matched bolt, nut
parallelism relation in grade. So it is very easy to find and two washers are supplied as a complete set (shown in
suitable bolts for replacement. TABLE 2-1 is another Figure 2-8, a set of bolt connection with grade 10.9).
comparison table for bolt grade in different standards. There are firm requirements on the bolt application, and
The strength grade is usually marked in the head and end only some simple knowledge is offered in this chapter,
of the bolt (shown in Figure 2-8). Bolts used in the crane for more detail information please refer to the related
are usually greater than or equal to grade 8.8, so less bolts criterion. As for the bolts ASTM A325 and ASTM A490，
can not to be used in the maintenances.。 the《Specification for structural joints using ASTM A325
or A490 bolts 》written by AISC can be referred to.
It must to be noted that the grade classification as Pretightening torque is required for many bolts and it is
mentioned above is suited for the bolts with the material realized by using a calibrated torque wrench. As listed in
carbon or alloy steel, and it is different from the Figure 2-9 are some typical torque wrenches.
stainless-steel bolts. Detail information please refers to
other related data. Generally stainless-steel bolts with
grade A2-70, nuts and washers are used when the bolts
are less than M14 in the crane, so the same grade bolts
shall be used in maintenances.
Table 2-1： SAE Grade and ISO Grade

ISO898-1 SAE J429 ISO898-2 SAE J995
Bolt Bolt Bolt Bolt
Figure 2-8：10.9 Grade fastener for structure
Grade 4.8 Grade 1 4
Grade 5.8 Grade 2 5 Grade 2
Grade 6.8 6
Hand torque wrench Hydraulic torque wrench Electric torque wrench
Figure 2-9：Typical torque wrench
aimed to insure the bolts loaded uniformly. Replace the

2.4.2 Inspection of bolts bolts having yield and been lengthened or the
deficiency-worried ones. Specification should be carried
For cyclic loading in working the bolts may be out during the downtime of the crane. There are two
loosened. In order to reduce stress amplitude, the bolts
methods about the fastener specification：visual check
shall be pretightened to set value. Periodic inspection is
and using wrest wrench，and visual check is mostly used.
2- 7
2.4.2.1 . Visual check 3) Mark the original location by a marking pen on

the nut and on the joint surface of the structure
Using the following methods to visually checking, refer and the washer (shown at Figure 2-11 ).
to the Figure 2-10:
Figure 2-11：Marked bolt
4) An initial tension of 75% of the final tension

shall be developed. Then the final tension shall
be developed.
2
5) Check the nut: if the nut can be turned, make it
out by a marking pen or painting and refasten
or replace it later on.
6) If needed, the bolt joint should be replaced.

3
7) Repeat the process 3)-6) to inspect the other
bolt joints.
8) The rotating nut should be refastened after the

Figure 2-10：Methods of Finding a Loosened Bolt loosing the bolt and according to the methods
mentioned in the section 2.4.3.3-A
1) The sound of a pointed hammer hitting the
head of a bolt can indicate the looseness 9) The non-rotating nut should be refastened
/tightness of the bolt. according to 10) ~11) step by step.
2) The position between the nut and the 10) Turn the nut about 30°by a torque spanner to
connecting part should be visually checked loosen the nut.
(during the fabrication in the ZPMC’s facility,
the positions between some critical nuts and 11) Refasten the nut to its pretightening torque
connecting parts will be marked out with a requirement.
marking pen). If the marking positions are
deviated, it indicates that the bolts are loose. 12) Remove all the dirt and use the proper solvent
to clean bolts, nuts, washer and places around
3) The paint film of nuts and connecting parts can the joint surface of the structure, and then
also be visually inspected. If the paint film has repair the damaged paints according to paint
fracture, the bolts should be inspected. repairing process.
2.4.2.2 Use the torque spanner B. Fasteners structures （ take the flanged
connection as an example）
A. Common fasteners（excluding the Fasteners
used for metal structures） 1) Before inspection, make the crane under
stopped state and make the bolts idly without
1) Before inspection, the crane should be off working stress (without loading).
working and make the bolts idly without
working stress.
2) If needed, remove all the dirt and paint on the
fasteners. Spray a thin layer of oil-lubricant
2) If needed, remove all the dirt and paint on the rust remover (CRC or other equate product) on
fasteners. Spray a thin layer of oil-lubricant the nut and washer. The lubricant rust remover
rust remover (CRC or other equate product) on is functioned after 10~20 minutes.
the nut and washer. The lubricant rust remover
is functioned after 10~20 minutes.
3) Use a marking pen to mark out the original
position on the nut and the surface between the
2- 8
connection part and the washer (shown in the After the crane is put into operation for six months
Figure 2-11 ). or 50000 hours work circulations, the tightness of bolts
should be checked according to Table 2-2. Because
4) An initial tension of 75% of the final tension the bolts are easy to be loosened in the primary stage, so
shall be developed by a marked torque wrench. an all-around inspection should be carried out.
High-strength bolts should be spot-checked by 10% for
5) Check the nut: if the nut can be turned, make it
each group. If any one bolt is found loose, all bolts within
out by a marking pen or painting and refasten
this group should be thoroughly checked. In addition, the
or replace it later on.
bolts bearing vibrating or varying load and the effective
6) Repeat the process 3)-6) to inspect the other anti-loosening methods have not been adopted, the
bolt joints. inspection period should be shortened to avoid accidents.
Electrical wiring and connecting bolts of small electrical
7) Account all the nuts that marked rotation and parts, such as bar wiring connection in control panels,
should be replaced. motor wiring, junction box wiring, various kinds of limit
switches, encoders and cam limit switches (inside and
8) If the account of the bolts marked to be outside), usually have smaller area and size. Impact and
replaced exceeds 20%, use the same grade vibration during the operation of the crane may cause the
bolts to replace them according to the process bolts to loosen. Once the bolts are loose, the electrical
mentioned in the section 2.4.3.3-B. control will fail. Therefore, the inspection of fastening
condition for this kind of bolts must be carried out, and
9) If the account of the bolts marked to be the wiring condition should be inspected periodically.
replaced under 20%, replace all the marked
bolts and the bolts on both sides, and refer to 2.4.3 Process for bolt’s replacement and
the process in the section 2.4.3.3-B. tightening
10) The non-rotating nuts should be refastened 2.4.3.1 Replacement standard
according to 11) ~13) step by step.
11) Turn the nut about 30°by a torque spanner to The bolts under the following condition should be
loosen the nut. replaced：
12) Refasten the nut to its pretightening torque 1) The bolts required to be replaced mentioned in
requirement. the above section.
13) Use proper solvent to clean the bolt, nut, 2) The bolts with such defects like impairment,
washer and the joint surface of the structure. distortion, slide tooth, lacking tooth, corrosion,
Then repair the paint according to the “paint big change of the screw roughness and so on.
repair process” mentioned in the appendix A.
3) If the bolts following out the standard
GB1228、GB1229、GB1230 ASTM325 and
2.4.2.3 Inspection period for the fasteners
ASTM490 are hot dipped galvanizing, they are
not allowed to be used repeatedly, and should
Table 2-2：Inspection Period for the Fasteners
be replaced once loosened after being final
Inspection Period Inspection Period tightened. According to the standard AISC only
Inspection
（before the first （after the first the bolts by black finished can be used again
Type
maintenance）* maintenance）* with engineer’s permission. In addition, when
Per 3 months Per 6 months the adjacent bolts are loosened by tightening
Visually
（except special （except special bolts, they are not needed to be replaced.
check
sites） sites）
10% 2.4.3.2 Tightening torque for the bolts
spot-checked (the the 5th, 15th、
Use torque th As listed in the table 2-5 is the tightening torque for
sixth month or 25th、30th、35
spanner th the bolts, studs and screws. if no special requirement, the
50000 hour in year
work circulation) data in the table can be used directly. Pretightening torque
Replace Mo ＝ K*Fo*d (K is the torque factor, Fo is the
If needed If needed pretightening force and d is the bolt diameter). The
fasteners
* The first maintenance here gives priority to the first friction factor of the nut and washer, the nut and bolt
expiration of the 6th month and 50000th hour in work changes will cause the torque factor change
circulation. correspondingly, so even when the required pretightening
force is unchanged, but the torque factor is changing.
2- 9
Generally under dry connection, the torque factor K＝ and measuring through experiments. Before finishing
0.145, if a little lubricant or MoS2 is filled, K=0.12. For tightening the fact torque factor of all the high-strength
the important connection, the torque factor is got by bolts or other similar connection should be measured.
spot-check of the each bolt or that of the same connection
2- 10
Table 2-3：Tightening Torque of Stainless Steel Bolts with Small Size (Grade A2-70)
Size M5 M6 M8 M10 M12 M14
Tightening torque (Nm) 3.2 5.5 13 26 46 74
Table 2-4：Tightening Torque of Major Bolts
Note : * = without lubrication ** = with a little lubricant or MoS2 lubrication

Tightening torque (Nm) Tightening force (N)
Size * ** * **
8.8s Grade 8.8s 10.9s 10.9s 8.8s 10.9s
M 12 66 54 92 76 37766 53109
M 14 105 87 147 122 51520 72450
M 16 163 135 229 190 70336 98910
M 18 225 186 316 261 86016 120960
M 20 318 263 448 370 109760 154350
M 22 433 358 609 504 135744 190890
M 24 550 455 774 640 158144 222390
M 27 805 666 1132 937 205632 289170
M 30 1093 905 1537 1272 251328 353430
M 33 1488 1231 2092 1731 310912 437220
M 36 1911 1581 2687 2224 366016 514710
M 39 2473 2046 3477 2878 437248 614880
M 42 2851 2360 4009 3318 468168 658362
M 45 3818 3160 5369 4443 585109 822809
M 48 4593 3801 6459 5346 659973 928087
M 52 5937 4913 8349 6909 787401 1107282
The torque listed in the table is only suit for the connection surface without special requirements. The
bolts in such connection are only bearing pretightening force, and the working force is vertical to the
bolts and transferred through the friction from the connection surface. For those bolts bearing not
only the pretightening force but also the working force, for example the bolts used in the bearing
pedestal and the motor base, the pretightening force should be recalculated (the tightening torque is
often less than the one listed in the table), please refer to the related drawing.
shall be developed. To ensure the flange bolts

2.4.3.3 Bolt fastening and replacing process load equally, fasten the blots in the order from
the rigid joint to free end or form the center of
A. Fastening process of the general blots the bolt group to around. If the connection steel
(excluding the high strength bolts for structure) plate warps and the connecting bolts are
during the first installation or replacement. fastened from the two ends to the middle, the
middle of splice plate may plumps up and can
1) Ensure the washer be planished and clean not keep closely which will make friction
without oil dirt and burr. forces lose partly. For detailed fastening
process refer to figure 2-12. Make marks on
2) Clean the connecting surface of the structure the large hexagon head and high strength bolts
and washer and ensure the surface be smooth. to identify their first fastening to avoid
missing.
3) Clean the bolts and nuts.
6) Finally fasten the blots to 100% required
4) Set well the washer and ensure the inclined torque. The fastening order is similar to the
plane touch the bolt head or the nut. first one. Generally use two kinds of color to
5) An initial tension of 75% of the final tension distinguish the first and final fastening.
2- 11
B. Replacement of the high strength bolts for

structure（flange connection）
1) To ensure the same torque factor, the bolts

replaced one time should be the same batch
products.
2) Ensure the bolts be enough in quantity, have

the correct strength degree and tightening
torque. Revise the torque wrench repetitiously
before using.
3) Ensure the washer be planished and clean figure 2-12：Fastening order of the flange
without oil dirt and burr. bolts
4) Clean the joint surface of the structure and 2.4.4 Anti-loosing methods for bolts
washer and ensure the surface be smooth.
It is very important to adopt some methods to
5) Clean the bolts and nuts. prevent bolts from loosing. If the bolts are loosened, the
structure strength will be reduced and the downfallen
6) Use a new bolt to replace the old one which bolts will bring danger to persons. Table 2-5 lists the
marked to be replaced and an initial tension of main anti-loosening methods for the bolts used on the
75% of the final tension shall be developed container crane.
immediately. Ensure the blots to be replaced
and fastened one by one. 2.4.5 Pin connection
7) The old bolts being taken down should be Pins shall be well greased prior to each installation.
destroyed purposely to prevent from using After the installation, this process is to be repeated at all
again. accessible spots of the pin.
8) After all the bolts being replaced, the final

tension shall be taken to all the new bolts in the
order shown in figure 2-12.
Table 2-5：Anti-loosening methods of the bolts used on the container crane
METHODS Instruction /application Figure for example
using The anti-loosing glue is often used in the fields with
anti-loosing limited place, for example used on the fixing bolts of the
glue anti-abrasion block for the wire rope.
Both of these methods are comparatively reliable and

Lock washer have been widely used. Such methods are commended to Correct
and be used in the fields without space restriction for example
on the running or moving parts like braking disk, sheave
Fastening with and so on to prevent it from falling or flying off when the
wire rope bolts are loosened.
Wrong
Nylon Nylon anti-loosing nut is the most widely used and it is

anti-loosing nut reliable to anti-loose when matching with bolts.
SPL nut SPL nut has a strict requirement on the retightening

torque and the nuts can be reused.
Double nuts
Double nuts are not used commonly on the crane for
inconvenience.
2- 12
METHODS Instruction /application Figure for example

Spring washer Spring washer is not very reliable and usually generates
or other yellow water when used outdoors. Usually they are not
anti-loosing used in ZPMC’S crane. But in some outsourcing or
washer unimportant parts the stainless steel washers are still used.
sound level of the components to determine whether the

2.5 Lubrication components get enough lubrication. The lubrication of
wire rope will be described in Chapter 4.
2.5.1 Summarization
2.5.2 Lubricant
Attention: All used oil and grease must For well effect of lubrication, the type of lubricants
be collected and disposed properly! must be selected properly. Consistency should be
maintained on lubricants. Do not mix up different
lubricants together. If the lubricant supplier, type or grade
Lubrication is a very important maintenance task. It is changed, launder the bearing, reducer, pin, and other
will determine the normal service and endurance life of devices thoroughly to remove the previous lubricant. If
the components. Proper lubrication practice will help to different lubricants are mixed together, please contact the
avoid premature wear and extend the endurance life of lubricants supplier.
the components. Lack of lubrication will destroy the
components. For example, if an anti-friction bearing is The lubricants and grease used in the crane are listed
short of lubrication, it will be damaged in a very short in table 2-6~2-8. And the comparison of those products is
time. It is very important to monitor the temperature and also listed in the tables.
Table 2-6：Gear lubricants
40C viscosity code

Place
(mm2/s) name
Gantry Reducer,
ISO Boom hoist Reducer,

220 A1
VG 220
Hoist cable coil Reducer
Rope re-reeving Reducer
ISO Main hoist Reducer,

320 A2
VG 320
Trolley Reducer
Table 2-7：Hydraulic lubricants
40C viscosity code

Place
(mm2/s) name
ISO
32 B1
VG 32
Motor room pumping

station,
ISO
46 Gantry Wheel brake B2
VG 46
pumping station,
Back girder pumping station
2- 13
Table 2-8：Grease
Working
drop
point Place Code name
point °C
°C
Low-speed and high-loading
185 -20~+100
sliding bearing: Equalizer
190 -25~+120 C1
pin, other pin, hinge point,
etc.
185 -20~+100
Wire rope C2
190 -25~+120
High-speed bearing: Bearing
for Motor(the lubrication of
180 -30~+120
motor should abide the C3
288 standard afforded by the
motor supplier)
decrease 35% or ASTM

2.5.3 Lubricant replacement standard acid number
increase ≥0.4mgKOH/g D 974
normal heptane
The deterioration of the lubricant lies on the work ≥0.1% IP 316
thawless
frequency and the ambience.
sheet copper ASTM
Less than Grade 2a
In inspection of the lubrication or in the use of erodibility D 130
lubrication, replace the lubricant whenever sizable Chroma ≥2 than new ASTM
Chroma variety
quantities of any of the following conditions are found: lubricant D 1500
ASTM
humidity ≥0.1%
(1) Rubber-like deterioration D 1744
(2) Impurity 2.5.4 LUBRICATION PROCEDURE

(3) Metal powder and badly discoloring 1) When the reducer oil is changed, drain the used
oil while it is still warm. The tank floor must
(4) Emulsification be cleaned out with oil to remove deposited silt,
(5) Separation of mineral oil and saponification radicel metallic particles and oil residue. Use the same
(deterioration due to oxidation). type of oil to keep normal operation.
In addition, sample specimen termly as follows to 2) When bearings are re-lubricated, pump the new
determine whether the lubricant should be replaced: take grease into the oil pocket through grease fitting.
approximate 20 milliliters of lubricant from the machine Please clean out the old extruded grease after
and consult the lubricant manufacturer or deliver it to lab re-lubrication. During the first shift of
to check .The detail of standard is listed in TABLE 2-9, operation after re-lubrication, the lubricating
replace lubricant or append additives according to the test points should be cleaned.
result if any standard is met. Refer to sampling program
3) For lubricating motor, emergency brake,
to Section 2.6.5.
reducer and other outsourcing parts, please
Table 2-9： The standard of lubricant refer to their manuals.
replacement 4) Wire ropes should be under good lubrication
condition at all hours. Lubricating will prevent
the standard of Test
Test items the wire rope from corrosion and reduce the
replacement method
friction in rope strands between the wire ropes
kinematics and the sheaves and/or drums. The type of
viscosity variety Increase 15% or ASTM lubricant and application frequency varies with
o decrease 20% D 445 the rope construction, the operating conditions
(40 C)
and its functional application. For details,
please refer to TABLE B-1 in Addenda B.
2- 14
5) The quantity of oil/grease should be suitable.
6) For gear reducers (splash lubrication), the oil

level should be kept a little higher than the
central level between the highest and lowest
levels because the oil level will become lower
when the gear reducer is working.
7) For bearings and other relatively sliding parts,

it is natural that the old grease flows out of the
seal from one side when the new grease is
pumped in from other side.
8) Oil and grease complementary cycle. It has

relationship with the ambience, sealing
condition, working grade and operating
frequency of each part. For details, please refer
to TABLE B-1 in addenda B.
9) For reducers not used frequently, bottom

valves should be opened termly to inspect the
moisture content of the oil.
10) At the early stage of the crane is put into

operation, three samples should be collected
from the replaced old oil to analyze the
percentage of metal powder in it. Compare
and analyze the lubricant to find out the
working status of machine.
2.5.5 Lubricating points layout

Figure 2-13 and figure 2-14 gives the assembly to
be lubricated, the amount of lubricating points and
the style of bearing at lubricating point. There are
relationship between the figures and Table 2-10.
2- 15
Figure 2-13：lubricating areas plot lubricating points layout
Figure 2-14：lubricating points layout
2- 16
2.5.6 Lubricating frequency

The lubricants and lubricating frequency are listed in condition. The maintenance people should observe
Table2-11. Lubricating frequency has relationship with the whether the lubricating is enough during the cranes service,
weather such as temperature and rainfall, and the service to protract or shorten the lubricating periods properly.
condition of the crane at the terminal. The lubricating Refer to Figure 2-13: Lubricating areas plot and Figure
frequency listed in the table can be used in common 2-14 Lubricating points layout while using the table.
The lubricating frequency listed is based on ZPMC’s experience and common condition. Please keep an
intact note or log. Based on the maintenance note and well lubricating condition, the lubricating frequency
can be redefined or changed.
The interval of lubrication is at most 4 years commonly. After this period, the lubrication should be
changed even if the lubrication is not metamorphosed. Refer to the lubrication suppliers’ recommendation.
Sample the hydraulic oil and gear lubrication while the recommended replacing period listed in table 2-13
is reached. If the sample shows that the lubrication needn’t be changed, the lubrication can be used while
monitoring should be reinforced. What’s more, gear lubrication should be sampled every 2 years even if
the replacing period is not reached.
The lubrication of forestay is very important for keeping well working status. If there is rust on the friction
surface between the pin and stay bar, appended bending moment will be engendered in the stay bar while it
is turning, and flaw can be engendered and expanded. So please remove ancient grease and add new grease
every month.
Table 2-10：Lubricating frequency

symbol：
D Daily 3M Every three month or～1000 hours
W Weekly 6M Every six month or～2000 hours
M Monthly ～or 300 hours A Annually or～4000 hours
H According to working time (hour) or else
Abbreviation of lubrication （Refer toTable2-7～Table2-9）
A1 Shell Omala S4 GX 220 A2 Shell Omala S4 GX 320
B1 --- B2 Shell
C1 Shell Omala S4 GX 220 C2 ChangCheng
C3 Refer to Motor manual
Abbreviation Of Lubrication Points Types：
Ⅰ Hydraulic Ⅱ Gear
Ⅲ Common anti-friction Bearing Ⅳ Motor Bearing
Ⅴ Sliding Bearing Ⅵ Chain drive
Ⅶ Gear Coupling or Spline Ⅷ Wire Rope
Ⅸ Others such as spring, seal…
 Refer to drawing / correlative independent
part maintenance manual
2- 17
Lub period
ri-ca lubrica am
tion nt (code Lubrication point style / remark oun 
3M
6M
Ｗ
Ｍ
Ａ
D
H
poin name) t
tP
1 ● C1 Ⅴ/door hinge 4
2 ● C1 Ⅴ/hinge 1
3 ● C1 Ⅸ/spring 2
4 ● C1 Ⅲ/hoist block bearing 4
5 ● C1 Ⅴ/crank handle 4
Refer to Gantry cable
6 --- Gantry cable coil - coil maintenance
manual
Refer to Elevator
7 --- Elevator -
maintenance manual
Refer to Load handling
8 --- Load handling device device maintenance
manual
9 ● C1 Ⅴ/hook beam pin 2
9a ● C1 Ⅲ/ hook beam thrust bearing 1
9b ● C1 Ⅴ/high tower rotate pin 8
10 ● C1 Ⅴ/equalizer pin 112
11 ● B2 Ⅰ/gantry wheel brake pump 2
Refer to motor
11a ● C3 Ⅳ/pump driving motor 4
specification
12 ● C1 Ⅴ/spud pin 12
13 ● C1 Ⅳ/wheel bearing 64
13a ● C1 Ⅴ/motor pedestal pin 32
Refer to motor
14 ● C3 Ⅳ/gantry driving motor 32
specification
Ⅱ/gantry reducer：400～500h for Refer to reducer
15 ● A1 16
the first time，then 5000h maintenance manual
15a ● C1 Ⅸ/reducer seal 32
Ⅱ/toothed clutch & cam limit
16 ● C1 2
reducer
17 ● C1 Ⅲ/ boom hoist drum bearing 1
18 ● C1 Ⅶ/drum coupling 2
1
19 ● C1 Ⅸ/reducer seal 4
Ⅱ/ boom hoist reducer：400～500h
20 A2 1
for the first time，then 5000h
Refer to motor
21 ● C3 Ⅳ/ boom hoist driving motor 2
specification
Ⅱ/ boom hoist emergency reducer： Refer to reducer
22 A1 1
replacing per 4 years maintenance manual
Ⅳ/ boom hoist emergency driving Refer to motor
23 ● C3 2
motor specification
2- 18
Refer to motor
24 ● C3 Ⅳ/pump driving motor 2
specification
25 ● B2 Ⅰ/drum brake pump 1
Refer to motor
26 ● C3 Ⅳ/trolley emergency driving motor 2
specification
Ⅱ/ trolley emergency reducer： Refer to reducer
27 A1 1
28 C1 Ⅸ/ 1 trolley reducer seal 3
Ⅱ/ trolley driving reducer: 400～
29 A2 1
500h for the first time，then 5000h
30 ● C1 Ⅶ/drum coupling 1
Refer to motor
31 ● C3 Ⅳ/ trolley driving motor 1
specification
32 ● C1 Ⅲ/ trolley drum bearing 1
Refer to motor
33 ● C3 Ⅳ/ re-reeving device driving motor 1
specification
Ⅱ/ re-reeving device reducer， Refer to reducer
33a ● A1 1
34 ● C1 Ⅴ/re-reeving drum sliding bearing 6
Ⅲ/ traveling crane gantry wheel
35 ● C1 8
bearing
Ⅲ/ traveling crane trolley wheel
35a ● C1 8
bearing
Ⅱ/maintain traveling crane gantry /
Refer to reducer
36 ● A1 trolley reducer，replacing per 4 4
maintenance manual
years
Refer to motor
37 C3 Ⅳ/ gantry / trolley driving motor 4
specification
Ⅷ/ maintenance traveling crane
37a ● C2 1
wire
38 ● C1 Ⅲ/ hoist drum bearing 2
Refer to motor
39 ● C3 Ⅳ/ hoist driving motor 4
specification
40 ● C1 Ⅸ/ 1 hoist reducer seal 4
Ⅱ/：hoist reducer: 400～500h for Refer to reducer
41 A2 1
the first time，then 5000h maintenance manual
41a ● C1 Ⅵ/ hoist emergency chain drive 1
Ⅱ/ hoist emergency reducer, Refer to reducer
42 ● A1 1
Refer to motor
43 C3 Ⅳ/ hoist emergency driving motor 2
specification
44 ● C1 Ⅳ/ hoist drum bearing 2
Refer to fan
45 C3 Ⅳ/ fan motor 2 specification，
self-lubricating bearing
46 ● C1 Ⅲ/ electric jib crane bearing 1
47 ● C1 Ⅲ/ hoist level sheave bearing 8
48 ● C1 Ⅴ/ equalizer pin 8
49 ● C1 Ⅲ/ hoist vertical sheave bearing 16
50 ● C1 Ⅲ/ main trolley wheel bearing 8
2- 19
Ⅴ/ trolley guide sheave sliding

51 ● C1 16
bearing
Refer to sling cable ceil
52 --- Sling cable ceil 1
manual
53 ● C1 Ⅲ/ idler bearing 70
54 ● C1 Ⅴ/ level guide sheave 16
55 ● C1 Ⅲ / hoist sheave bearing 12
56 ● C1 Ⅴ/ ball bearing 4
57 ● C1 Ⅴ/ pin shaft 16
58 ● C1 Ⅴ/ rocker pin shaft 2
58a ● C1 Ⅴ/ cylinder ball bearing 4
59 ● C1 Ⅲ/ trolley sheave bearing 2
Refer to motor
60 ● C3 Ⅳ/ pump driving motor 2
specification
61 ● B2 Ⅰ/ multifunctional pump 1
62 ● C1 Ⅴ/ pull rod pin shaft 12
Refer to trolley
63 - Cable trolley 1
maintenance manual
64 ● C1 Ⅴ/ pin ball bearing 4
64a ● C1 Ⅸ/ below pin shaft 2
66 ● C1 Ⅲ/ boom sheave bearing 8
70 ● C1 Ⅲ/ hoist sheave bearing 2
73 ● C1 Ⅲ/ hoist guide sheave bearing 4
77 ● C1 Ⅲ/ boom sheave bearing 2
78 ● C1 Ⅴ/ back pull rod pin shaft 2
78a ● C1 Ⅴ/ back pull rod pin shaft 10
79 ● C2 Ⅷ / boom wire 1
80 ● C2 Ⅷ / hoist wire 2
81 ● C2 Ⅷ / trolley dragline 2
Attention: To oil seal lubrication, add grease according to the direction of nameplate near the oil fitting, to avoid redundant
grease come into the tank and mix with the gear lubrication.
2- 20
2.6 Prevention and inspection 2.6.1 Summarize
In order to ensure reliable crane operation and The inspection is used to judge whether the crane is in a
prolong the crane’s life, each component on the crane safe and reliable state. It is basically a visual inspection
must be operated correctly, and a proper maintenance and functional test. If an adequate assessment is not
schedule must be followed. To keep up the operating possible by this, further tests have to be taken, e.g.
status and operational safety of the crane, please nondestructive testing. If necessary, disassemble the crane
accomplish the maintenance of the crane at regular parts to observe the hid parts. The description of the crane
intervals listed in the rear of the chapter. The crane components disassembly and re-assembly is listed in
routine maintenance and inspection can be started with Chapter 3. When performing inspection and maintenance
the following aspects. on the crane, the appropriate preventive actions should
be taken according to Table2-11.
The abnormal temperature, sound, or libration
can be the omen of failure, abrasion or mangle. The
following sections list the detail.
Table 2-11：Preventive action (mechanical)

Inspection Items Contents of Inspection Preventive Action
Apply grease if poorly greased.
Grease on gear
Gear Realign if out of tolerance
Alignment
Gear coupling Adjust the attachment if engagement is not proper.
Gear engagement and wear
Replace excessive wear ones
Sliding surface of bearing, Apply if necessary so that respective lubrication points
Lubricating condition
sheaves, wheel, pins, lever are lubricated as required.
pins, etc. Wear condition Replace if wear is excessive
Bolts, nuts, keys, pins, Looseness, Attachment Tighten sufficiently.
shaft coupling bolts condition of split pin retainer Replace if quality is deteriorated
Lubrication Add oil if the amount of oil is low.
Gear box Temperature Replace if quality is deteriorated.
sound Check abnormal sound
Lubricating condition, broken Apply grease as necessary if grease is insufficient or
Wire ropes wires, degraded.
abrasion See Section 3.4.9 for wire rope inspection.
Tighten loose bolts with specified torque.
Wire rope end termination Condition of wire end
See Section 3.4.7
High strength bolts, and Looseness Replace if loose.
welding for steel structure Crack, damage Repair if crack or damage is observed.
Brake lining Wear, fitness to brake disc Replace if wear is excessive.
Brake disc Wear of sliding surface Repair if sliding surface is worn or rough.
Bolt looseness, Tighten loose bolts with specified torque,
Track and track clip Track abrasion, Replace excessive wear ones,
Track distortion Realign
Hook, headblock, lock pin Abrasion,
Replace excessive abrasion ones or ones with crack
in the spreader crack
Sheave, drum, idler Abrasion Replace if wear is excessive
Other consumable Abrasion, Replace if wear is excessive,

parts(such as seal, bulb） damage Repair or replace damaged
Steel structure Crack, paint, etc. Refer to Steel structure maintenance manual
Safety device Any abnormity Repair while there is abnormity.
2- 21
the disc)
The crane and its additional equipment, 6) Hydraulic thruster oil internal leakage.
primarily the safety devices, have to be 7) Abnormal operation of the relief valve.
checked for proper condition and
function depending on work use. It
requires special supervision of: −
emergency-stop button and control; −
drive & brake; − electrical equipment; −
limit switch and overload protection.
2.6.2 Inspection of temperature rise

Temperature rise is a phenomenon. Maintenance
personnel who well understand the temperature rise
condition can judge the working condition of the crane. If
there are no otherwise specifications, the temperature rise
of the bearing should not exceed 60 ºC (140ºF) and the Figure 2-15：Infrared thermoscope
absolute temperature of the oil should be less than 85 ºC
(185ºF). Infrared thermoscope is in common use. See 2.6.3 Inspection of abnormal noise
Figure 2-15. The following temperature raise locations on
the crane should be carefully inspected: The main cause of mechanical noise is vibration, impact
noise, friction noise and structural transmitting.
1) High-speed rotation supporting locations, such Maintenance personnel who understand the noise change
as the motor bearings and the high-speed shaft can judge the operating condition of the crane through
bearing of reducers mainly used in main daily noise observation. Generally, the abnormal noise
hoisting and trolley. may be caused by improper gear meshing, bearing
damage, loose bearing clearances, shaft bending, loose
2) Heavy-load and slow speed supporting bolts, interference or motor fan damage, lack of
locations, such as reducer low-speed shaft
lubrication, etc.
bearing, drum bearing pedestal, wheel bearing
and sheaves bearing. Noise can be identified/isolated by using an
industrial stethoscope.
3) Hydraulic actuator temperature rise, such as
the hydraulic thruster of the brake (especially Noise measurement directly with ear
hydraulic thrusters of main hoist and trolley may be harmful to ears, so only do this
travel mechanisms), the relief valve and the when necessary and for a short period.
throttle valve.
Generally, the abnormal noise and temperature rise
4) Hydraulic oil reservoirs, such as the
happen simultaneously, such as when the bearing
multifunction pump, emergency brake, gantry
clearance is too big or the brakes are not fully released,
wheel brake, and sling hydraulic units.
and so on. Therefore timely noise inspections can avoid
Normally, the inspection of temperature rise many equipment failures.
condition can be achieved by hand touch and judging if
the temperature is abnormal. When there is abnormal
2.6.4 Inspection of abnormal vibration
temperature rise, it is often accompanied with abnormal Vibration is usually related to noise and element fatigue.
noise. If there is abnormal temperature, specialized Close attention should be paid to the abnormal vibration
thermometer should be used to measure and to aid in during crane inspection, such as for the motor base, gear
finding the cause of temperature rise. Only after the reducer base and drum support rigidity, base rigidity, bolt
problem is solved, should the operation be resumed. pre-tightening, misalignment of motor and gear reducer,
dynamic balance of coupling and static balance of drum.
Generally, the causes of temperature rising are:
The inspection sequence is generally started with the
1) Improper lubrication.
check of alignment (radial and axial vibrations). If the
2) Improper gear meshing.
vibration still exists after adjustment, the coupling should
3) Bearing clearance is too loose or too tight (or be removed and the motor checked separately.
bearing damage)
4) The alignment coupling can’t meet standard. After causes of the motor and loose bolts are eliminated
5) Brake not fully released or not centered (one and dynamic balance of coupling are checked, the
side released but the other side still touching coupling can be connected and the high-speed shaft
2- 22
bearing of the gear reducer and should be driven and inspect pre-determined regularly inspecting locations. If
checked. Generally, the problems caused by improper there is any suspicion after visual inspection, MT or UT
gear meshing and lack of adequate rigidity of the inspection can be applied. Please refer to the Steel
installation base can be found during test running. Structure Maintenance Program for details. Driving or
connecting parts can also be checked during maintenance
If the vibration happens after the crane is put into when they are knocked down.
operation for a certain period, loss of alignment, loose
bolts, excessive bearing clearance or improper gear 2.6.6 Inspection of rail & rail clips
meshing usually cause the vibration problem.
2.6.6.1 RAIL INSTALLATION TOLERANCES
2.6.5 Inspection of crack
Crack inspection sometimes can prevent failure or When designing a complete container handling system,
disaster of a crane at its early phase. The inspection of the problems of the crane rail track never appear to be
crack consists of inspection of the driving parts, the insignificant, and that is important to crane’s using.
connecting parts and the structural parts. The cracks are
Failures of rails, to a great extent, can be attributed to
normally caused by fatigue and happen on locations of
improper lying of rail during foundation work or the
fatigue source, stress concentration, and repeated stress
crane or trolley may not be tracking accurately. If the
effect.
crane is used with curved or uneven leveled runway rails,
Driving parts: such as driving shaft, wheel, gear, its structural members can be twisted causing high
sprocket, sheave, coupling, braking wheel (disc), bearing stresses. Accordingly, the bolts in joints may be loosened
and so on. and the bases of the various machines on the steel
structure may be distorted. Thus, crane performance may
Connecting parts: such as fixed shaft, wheel shaft, be impaired.
sheave shaft, structural connecting pin shaft, headblock
connecting pin, spreader twistlock and so on. In order to prevent such troubles, at the time of
annual inspection, measure the level, straightness, span,
Structural parts: welding seam and base material. etc. of the trolley travel rail and gantry travel rail and
keep their records. Also, carefully inspect the trolley
The method of structural inspection can be visual travel rail and gantry travel rail for cracks. If measured
inspection, which can be judged through the surface paint dimensions are not within the allowable tolerance in
film. If the base material or welding seam is cracked, the Table 2-12 or Table 2-13, immediately repair or replace
paint film will be also cracked. Telescope can be used to the gantry or trolley travel rail.
Table 2-12 Allowable Tolerances for Gantry Rails
Inspection items Measuring Method Maintenance tolerance
Measured by a transit
Straightness d1=±10mm
or piano wire
Measured by a steel d2=5 mm

Span (S)
tape measure S-theoretic span=30500mm
Height d3＝H0±15mm
difference Measured by a transit (H0：original height difference＝
between rails 0)
Measured by a transit
Bend of rail left or piano wire
d4＝±10 mm
and right LH+RH<
Tolerance
2- 23

d5＝±25 mm
In the nominal span and wheel

base of the crane no point on any
Levelness Measured by a transit rail will be greater that ±25mm
out of the common plane
established by the other three
corners of the crane.
1
≤ (check evry
Inclination Measured by a transit 400
10m/32.81ft)
Joint Measured by a steel d6＝±0.5 mm

difference ruler
deviation d7＝±0.5mm
Joint gap & Measure by a steel Gap d8＝4mm or so
deviation ruler No contact even in Summer
Table 2-13：Permissible Tolerances for Trolley Travel Rails

Measured by a steel d2=3 mm

Span (S)
ruler S-theoretic span=6300mm
Difference in Measured by a transit d3＝±9.45 mm

height or piano wire 0.15% of span
Measured by a transit d4＝±1mm

Slope or grade
or piano wire
Difference
Measured by a steel d 7＝±0.5mm
between boom
ruler
and girder rail
Difference d 7＝±0.5mm
Measured by a steel
between boom d 8＝4±0.5mm
ruler
and girder rail
2- 24
Center distance
Measured by a steel d9≤＝t/2＝±6mm
between boom
ruler
and girder rail
0.1% of span
Measured by a steel
Levelness d10≤6.3
ruler
[0.248 in]
2.6.6.2 TROLLEY RAIL CLIP INSTALLATION AND

INSPECTION
Mark
Inspect the bolts of rail clip to estimate whether they line
are loose. Screw down bolts if needed, and insure the
exact position of stud. The process of installation about
ZPMC trolley rail clip is listed hereinafter.
1) Welding of base. Weld the base all around

with low hydrogen electrodes and 4mm fillet Figure 2-17：Installation of bolts and clip
welding. Spot welding first, and then weld the
base. Especially pay attention to clamp the 3) Cleaning up of base bolt hole. Clean up the
base when welding to avoid the moving in rubbish (with air pump) and slag (with welding
upright direction and keep the contact of base. hammer) in the base bolt holes before set up
Refer to figure2-16. the clips. Refer to figure 2-18.
Figure 2-16：Welding of base

2) Installation of bolts and clip. Set the bolts into
the holes of clip base, circumvolve it 90° and
keep it lying in the wimble holes reliably. After
confirming the bolts are oriented reliably (pay Figure 2-18：Cleaning up
attention to the orientation line in the section of
bolts), install clip and screw down nut
4) Tighten the clip. Knock the clip slightly with
manually. (It’s important to screw down
hand hammer to keep the close contact of clip
manually to ensure the correct location of the
and rail side. Then, complete the tightening of
head of bolts in its head room.) Refer to
the nuts to 200Nm. In case of further painting
Figure2-17. Paint immediately just after protection, the use of solvent is prohibited.
tightening the nut( do not stay overnight). Refer to figure 2-19.
2- 25
2.6.7 Inspection of gantry & trolley travel

wheel
The gantry travel and trolley travel are indispensable
for operation by this machine. Therefore, it is important
to maintain the travel wheels and rail in normal state all
times. The following passages describe the inspection
procedure of the wheel.
The following items should be checked during the

daily, monthly, and annual periodical inspections.
1) Wear in treads and flanges
2) No flanges riding on rail
3) During traveling, both sides moving smoothly

in parallel
4) Abnormal noise or vibration
5) Wear in wheels, bearings, etc., developing

evenly for both legs.
6) Cracks or repair welding cracks in wheels.
7) No break in rail flange. No condition of more

than 3 places disfigurement with area over
3cm2 and depth over 30% of the thickness of
the rail.
Figure 2-19：Tighten the clip After inspection, if the wear of the gantry or trolley travel
wheel reaches the values indicated in Table 2-14 or Table
2-15, replace the wheel.
If, for any reason, a nut must be
loosened after mounting, you must verify
the correct position of the bolt shaft
before re-tightening the nut.
Table 2-14: Wear Limitation of Gantry Wheel
（these dimension are applicable at any place in tread）

Original Wear Limitation
dimension Driving wheel Driven wheel
780 or the difference of the 2 driving wheel 780 or the difference of the 2 driving wheel
D 800 D’
diameter is more than 1.6mm （0.2% D） diameter is more than 4mm（0.5%D）
h 25 h’ 35
b 127 b’ 145
a 26.5 a’ 17.5
2- 26
Table 2-15: Wear Limitation of trolley Wheel（draught trolley）
（these dimension are applicable at any place in tread）

Original
Wear Limitation
dimension
D 630 D 615 or the difference of the 2 wheel diameter is more than 3.2mm （0.5%D）
h 25 h’ 32.5
a 26 a’ 18.5
b 100 b’ 115
No wheel flange riding on rail is permitted. It will increase the travel resistance force up to 3
times as normal operation and will overload its driving system. If flange riding is observed,
check the gantry drive coordination or the waterside trolley tow rope length agreement.
Severe wheel flange riding on rail will cause damage to the wheel and rail. Eliminate flange
riding right away if it exist.
2- 27
2.6.8 Inspection of rope sheaves, drums, idler 1) Verify that roller rotates freely.
and slap block
2) Determine the anti-friction material is peeling,
2.6.8.1 SHEAVE aged or worn out. The wear resistant roller ring
shall be replaced when the amount of wear
If the following symptoms are found, check the reaches 60% of its original thickness. Make
wire rope for wear and replace the sheave at the same sure that the worn roller ring has been replaced
time of replacing the wire before the wire rope penetrates the thickness of
rope. the roller to expose the base metal of the roller
shaft. If this happens, the wire rope will rub
1) The flange is against the metal to cause the abrasion failure
damaged or of both the wire rope and the roller shaft.
deformed.
2.6.9 Inspection of the spreader
2) The wear in the
flange is 10% or As a direct performer of loading container, the load
more of the handling device’s reliability is very important. Please
diameter of the refer to the ZPMC load handling device manual to get the
wire rope used. information about the detail of the load handling device’s
maintenance standard. Following routine inspection to
3) A trace of the wire the load handling device are suggested in handing over or
taking over:
rope lay can be
Figure 2-20: limits of 5) The reliability of lock pin or shaft pin
observed at the
wear in sheave groove connected with upper-hanger and load
bottom of the
sheave grooves. handling device.
4) The wear in the sheave groove is 15% or more 6) Check the structure in the headlock and
of the diameter of the wire rope used.Refer to spreader to eliminate damage, incomplete
figure 2-20. fusion or weld crack in the parts easily to be
stroked.
Refer to Figure 2-20 for limits of wear in
7) Check lubricating condition on the slide
sheave groove. The symbol “d” indicates
surface of flex arm and slide rail.
the diameter of the wire rope used.
8) Lubricating and movement condition of key
2.6.8.2 DRUM parts such as twist lock pin and peak-pin,
reliability of twist lock pin locknut.
9) The tightness of all the limit-board of spreader,

the integrity of limiter, the correctness of
signal.
10) The reliability of cable used in spreader, and

whether there is sudden damage.
Figure 2-21: limits of wear in drum groove
11) The abrasion and damage condition of the head
1) Periodically check the drum groove for of twist lock of spreader.
corrugation and excessive wear.
12) The damage condition of guide-board of
2) The wear limit in the drum groove is 20% of spreader.
the diameter of the wire rope used. Refer
figure2-21. 13) The oil leakage condition of hydraulic system
of spreader, and the oil surface location in the
3) There should be no crack in drum groove, wire tank.
rope root point and drum axis.
2.6.10 Inspection of hook and twist lock pin
4) Inspection of rope support roller and Slap
Block The hook and twist lock pin become weaker against
crack due to wear and hardening caused by extended use.
The inspection of the rope support roller is described Therefore, perform the following inspection once a year.
as follows:
2- 28
2.6.10.1 Hook more than 10%.
Perform the magnetic flaw or die check. After 7) Deform or crack on the screw segment of the
inspection, immediately make appropriate repairs or tail of the hook.
replacement. Refer to figure 2-22:
2.6.10.2 Twist lock pin
1) Any bending or twisting by 10.
Perform the magnetic flaw detection or die check.
2) Any distortion causing an increase in throat Repair or replace the parts on condition listed hereinafter.
opening of 15%.
1) Crack, crevasse or hair-crack on the face of the
3) Any wear exceeding 10% of the original head of twist lock pin, shaft and the connect
section dimension of the hook or its load pin. root of the lock head;
4) Any self-locking hook that does not lock. 2) Damage or wear of the head of twist lock
pin;
5) Any latch that does not close the hook’s throat.
3) Deform or crack on the screw segment of the
6) Repair of cracks, nicks and gouges shall be tail of the pin.
carried out by designated person by grinding
longitudinally; following the contour of the Always Inspect A ○ and B ○ area with
hook provided no dimension is reduced by special care Refer to figure 2-23!
Figure 2-22: Annual check of cargo hook Figure 2-23: Annual check of Twist lock pin
It’s not permitted to repair the disfigurement in the hook and twist lock pin by welding. Replace the
failure part if there is un-repairable disfigurement.
2.6.11 Inspection of hydraulic handspike brake clean and not covered with oil dirt.
Brake should be inspected periodically with items 2) Whether the arm bars of the brake are flexible.
listed hereinafter:
1) Whether the brake lining and brake disk is 3) Inspect whether the belleville spring is broken
or hydraulic oil is leaked to the belleville
spring through inspection window of the brake
Attention! Hydraulic handspike brake
cylinder. Repair or replace the failure part if
cylinder has especial structure inside
the break or leak happened.
and connecting proprietary technology.
So don’t disassembly it yourself and 4) Inspect whether the push rod of the limit
avoid belleville spring collapsing and switch is loose and the action is right.
hurting the people. Replace the fault
cylinder as one piece.
2- 29
Shanghai Zhenhua Heavy Quayside Container
Industries Co.kLTD. Crane Crane Structure and maintenance Chapter 2
manual
5) Inspect the abrasion condition of the brake brake disc is contaminated. Any oil or grease on the disc
lining. If the attrited thickness of the brake must be cleaned with detergent or solvent immediately.
lining is over 40% of the original thickness of
the friction material, a new brake lining should Also check the brake disc surface roughness. If the
be set. disc is damaged, scoring or cracked, if anything is found
as shown in Table 2-16, the brake disc should be replace.
2.6.12 Inspection of brake disc
Inspection of the brake disc is very important to the

safety of the crane operation. Periodically check if the DANGER! Any grease on the brake disc
will cause the substantive drop of the
brake torque.
Table 2-16: Standards for Brake Disk Changing
Main Trolley Boom Boom hoist Main hoist

hoist drive hoist emergency brake emergency brake
Brake disc thickness 30mm 30mm 30mm 40mm 40mm
Wear limitation 27mm 27mm 27mm 36mm 36mm
Convex or concave on
2mm 2mm 2mm 3mm 3mm
the disc surface
Attrited thickness should not more than 40% of base thickness. Interface between
Brake lining wear limit brake lining and brake disk should not less than 75%. The brake lining with adust
face or aging should be replaced.
2.6.13 Inspection of shaft and axle sleeve

Some parts of the crane, such as stay bar pin and handle pin of gantry anchoring is equipped with shaft + axle sleeve
(copper sleeve commonly, sometimes copper sleeve with plumbago lubrication)。 Check if the pin and bushing are well
lubricated and rotates relatively freely. The relative rotation always happens between the bushing and the pin. The bushing
should stand still in the housing, so no wear should occur on the outer diameter of the bushing. The abrasion form of the
shaft and axle sleeve and the measure should be taken are
listed hereinafter.
(1) Sort according to the abrasion form which is shown in

figure 2-24.
1) symmetrical wear ①
2) wear induced by unilateralism load ②
3) wear induced by bidirectional load ③
4) wear only on the both sides ④
(2) Measure while the hole is worn.
1) replace the worn axle sleeve
2) deal with the worn shaft holes conform to the
steps listed hereinafter
i. bore the hole after repair welding Figure 2-24：Abrasion form of shaft hole
ii. enlarge the diameter of pin, axle sleeve, and
shaft hole
iii. replace axle sleeve
If the wear of the bushing reaches the amount shown in Table 2-17, replace it.
2- 30
manual
Table 2-17: The Wear Limits of Bushings
D Wear limitation Location Original Wear limitation

(mm) of dia. (mm) dia.(mm) of dia. (mm)
10～24 0.8 - - -
25～40 1.2 - - -
41～60 1.6 - - -
61～100 2.0 -  
-  
101~160 2.5 -  
161~250 3.0 -  
Stay Bar  
carry out the inspections below.

2.6.14 Inspection of oil seal i. Check if any causes of the temperature
rise exist, such as no relief clearance
Please check the oil seal if leakage is founded due to the one-side free bearing,
according as the description listed hereinafter. overloading, etc;
1) whether there has been appropriate seal set ii. If no abnormal condition is found,
in the leakage point; replace the bearing since the severe
condition such as an initial state of
2) Whether the brim seal is damaged by bearing damage etc. is suspected.
keyway, spring, screw, rough surface or the Especially the temperature rise with
brim of shaft; abnormal noise is considered to be a
sign of developing damage. Replace
3) Whether the seal is set in reverse direction; the bearing immediately in such a case.
4) Whether the deformation of seal is caused 3) If abnormal noise is found.

by setting with unsuitable tool;
If abnormal noise is heard from the bearing unit,
5) Whether the venthole is jammed. carry out the inspections below.
i. Measure the bearing block temperature.
2.6.15 Bearing unit inspection If the temperature is less than 20C
(36F) after subtracting the ambient
In the crane’s working, judge the state of the
temperature, check the retaining bolts
bearing housing during operation, then take the
for looseness and verify that there is no
following measures if abnormality is observed.
looseness between the bearing unit and
1) If vibration is found: the installation base. Tighten the bolts
if necessary.
If the vibration is severe, first check the retaining ii. If the abnormal noise remains after
bolts for looseness and verify that there is no procedure 1, the following causes are
looseness between the bearing unit and the suspected. Immediately replace the
installation base. Tighten the bolts as necessary. If bearing judging from the abnormal
the vibration remains after the above mentioned noise degree and the machine
procedure, check if the causes of other rolling importance.
element vibration such as bent shaft exist. If no  Slight wear appears on the track
abnormal part is found, replace the bearing unit surface and/or rolling element of the
since the excessive clearance due to wear inside bearing;
the bearing is suspected.  Inclination toward noise;
 Foreign materials inside the bearing.
2) If abnormal temperature rise is found: iii. Measure the bearing block temperature.
If the temperature is over 20℃ (36℉)
If the temperature of the housing rises over 20C after subtracting the ambient
(36F) after subtracting the ambient temperature, temperature, replace the bearing unit
2- 31
manual
since the developing peeling of the 2.6.17 Inspection of consumable parts

track surface or rolling element is
suspected. Consumable-parts are those parts which may be
depleted or worn out by use of the crane and they do
2.6.16 Inspection procedure of key and not belong to guaranty products. During crane
keyway maintenance and inspection, pay special attention to
the consumable parts listed as follows:
The key and keyway suffer various kinds of
damage according to the used condition. If and damage 1) Inspection of wire rope for abrasion, wire
is found on inspection, immediately replace the key. breaks and other damage. Refer to the
The damage types and their cause are as follows: relative provisions in Chapter 4.
1) Shearing of key 2) Check if there is any oil leakage from gear

seal rings.
The key may be sheared if the abnormal torque
that is larger than key strength is applied in such a case. 3) Inspection of braking shoe abrasion.
The keyway often may be deformed as well, so re-cut
the keyway and install the key with hardness of 4) Inspection of carbon brush of conducting
superior grade. ring (such as DC motor and spreader cable
reel slip rings).
5) Inspection of kryptol for trolley rail and

wheel lubrication.
6) Inspection of all lamp bulbs.
7) Make sure the spare fuses are available.

Figure 2-25：Shearing of Key
8) Inspection of filters.
9) Inspection of vulnerable parts, such as the

2) Crack of keyway spreader flippers.
The stress concentrates on the edges of the shaft or the

keyway in the fillet engaged with the shaft. Therefore,
cracks may be caused if the part suffers abnormal 2.6.18 Inspection of steel structural members
torque larger than their strength. If the condition
remains, the crack may be enlarged, resulting in The structural integrity of the crane
keyway damage of shaft failure. requires that no attachments or
fixtures of any kind be welded to any
part of the crane without prior written
approval of the responsible Structural
Engineer.
Please refer to Steel Structure
Maintenance Program for more
inspection information.
Figure 2-26：Crack of Key Groove
In order to maintain the crane in good condition,
continuing inspection is very important. When
3) Wear of keyway side damages occur to steel structural members, this crane
may be unusable and require detailed inspection. Not
The fatigue and deformation may be caused if only machine damage but also accidents including
abnormal torque is applied to the keyway sides and human injury may arise.
abnormally high surface pressure is struck on the
keyway sides repeatedly. Deformation of the steel structure members may
be caused by improper usage of the crane, development
of cracks, and loose bolts. Therefore, always follow the
operating procedures described in the container crane
operation instruction manual and conduct the
2- 32
Figure 2-27：Wear of Key Groove Side
manual
regular inspections as described in this manual. the structural engineers.
Inspection and diagnosis methods for metal 4) In order to prevent corrosion of the steel
structure: structure, clean clogged drain holes. Repaint
areas if there is any indication of rusting.
1) Inspect and judge the metal structure by Corrosion will reduce the thickness of the
human sense and experience: structural members, increase members stress,
and may create cracks. In order to inspect
 Check to find out whether the hinge points cracks in the structural members, thoroughly
and the interconnecting pieces run smoothly remove the rust and paints from the area,
and flexibly, whether have abnormal sound then conduct the indicated testing.
and blocking phenomenon, whether have a
good lubrication and a severe abrasion, 5) The lubrication of the stay bar pins is
whether the center axle have movement and essential to keeping the stay bars sound. If
so on. the rusting of the pin occurs on the stay bar
friction surface, the additional bending
 Check the bolts connection to eliminate
moment will be induced on the bar and may
loosening.
cause the initiation and propagation of
 Check the main connection pieces and cracks. Therefore, the lubrication must be
welding to find out painting crimple, made periodically to remove old grease and
spalling or welding cracking. to refill the new grease.
 Check the components to find out global or 2.6.19 Inspection of all safety protections
local deformation and bending, folding
Safety protections should be checked before any
twisting and damage phenomenon.
work.
2) Period inspection through non-destructive
1) Regularly inspect if the braking torque
detection should be carried out for the
setting-up of all brakes. Make a practical
welding of FCM pieces (for detailed
plan to periodically verify the braking torque.
information refers to STRUCTURE AND
MAINTENANCE MANUAL for QUAYSIDE
All slow-down limit switches and
CONTAINER CRANES). over-travel limit switches. Ensure that the
positions of all encoders, functions of all
3) Use electrical logging stress method to test interlock protections are correct.
the strength and rigidity of the metal
structure. Through careful and quantitative 2) Safety inspection of elevator according to its
inspection to make a scientific judgment on manual.
the working condition of the metal structure.
3) Regularly inspect the hoist over-travel limit
The following things should be paid much switches and hook of service crane.
attention to:
4) Visually inspect if all buffers mounting
1) Check deformation, corrosion, crack, loose condition and wheel stoppers are reliable.
bolts, etc. at the time of regular inspection
such as daily, monthly, and annual 5) Replace any missing or illegible warning
inspection. sign.
2) The deformation of steel structure can 6) Refer to Chapter No.1 to find out the
degrade the alignment of the machinery working condition of crane safety
installed on the structures, increasing equipments like the boom stowage device,
operating noise, causing improper gantry anchor device, tie down device and so
engagement of the gears, etc. on.
3) If some deformation of steel structures, 7) Check the function of the operator’s cab, and
development of cracks, loose bolts, etc. is check the headblock to find out crack and
observed, immediately report to the service loosing parts. Check the ladder rails to find
office, and repair it under the supervision of out the loosed or deformation bolts.
Never tamper with any safety protection

devices. It’s about your own safety!
2- 33
manual
2.7 Check list

This manual list the items that the crane need to check and maintain.Users can write down maintenance tasks for
reference. Users have more experience than quay crane manufacturers on maintenance work, we welcome good
maintenance advice or suggestions feedback to us, so that we can continue to improve maintenance tasks table, making
it more practical operability.
The following inspection / maintenance tasks based on checks / maintenance interval are divided into 10
categories rating. These intervals determined depends on the main components of crane itself property and their
wearing, damaging, and the level of failure frequency. According to the inspection / maintenance interval, 10
categories are defined as follows：
Table 2-18：Description of Listed interval

No. Type Description
running in Period after the overhaul of the trial run of the new purchase of quayside or shore
1
period bridge go together.
2 Dynamics Execute before, during or after working. Permanent maintenance.
3 Weekly Execute weekly or every 100 hours（whichever comes first）
Every two Execute every two weeks or every 150 hours（whichever comes first）
4
weeks
5 Monthly Execute Monthly or every 300 hours（whichever comes first）
6 Seasonly Execute every three months or every 1000 hours（whichever comes first）
7 Semiannually Execute every six months or every 2000 hours（whichever comes first）
8 Yearly Execute yearly or every 4000 hours（whichever comes first）
Every five Execute every sixty months or every 20000 hours（whichever comes first）
9
years
Every ten Execute every 120 months or every 40000 hours（whichever comes first）
10
years
2- 34
manual
Table 2-19: Running-in Period Task List (For Queyside Container Crane)
Equipment No.： start time： No.of checking sheet：
Checked by ： finish time： running hours：
serviced by： date： technical confirmed by：
no. checking part standard result process
whole crane
cleaning the dust and collecting the
1 cleaning missing tools on the crane to avoid
droping
2 marker hang "running-in period) marker
avoid emergency stop and other
3 emergency abnormal stop(electric power stop) in
running-in period
checking and testing every connecting
4 fastening parts. Do the fastenign or adjusting
again if need.
machinery house
reduce 10%-15% of the rated load, low
speed running for at least 50 hours,
1 three main parts' motor
smoothy accelerate and brake. No
emergency brake.
Apply the brake several times under no
load or 50% load, watch the
stabilization. Check content in
running-in period: 1.joint condition
emergenc brake (low of bush and brake disc; 2. disc
2
speed brake) temperature should below
350℃;3.looseing of screw connector;
4. limit switch operation; 5.running
and brake sounds should be normal;6.
no leakage for the hydraulic system.
Apply the brake several times under no
load or 50% load, watch the
stabilization. Check content in
3 high speed brake of bush and brake disc; 2. disc
temperature should below
and brake sounds should be normal
no leakage for the pipe and valve
manifold, reading from the gauge
4 hydraulic system should normal, cleaning the oil
reservior, filter and other valves
when changing oil.
5 High coupling no abnormal sound;bolts have no loosen
2- 35
manual
6 Drum coupling no abnormal sound;bolts have no loosen
no abnormal sound and glowing,

gear boxes for three
7 cleaning the box and filters when
main parts
changing gear oil
make sure no logic short-circuit or
8 electric boom constraint. Checking the readings
from the guage on the electric cabinet
running several times under no load
9 service bridge crane or light load , make sure running and
apply the brake smoothly
girder
multi-function
1 should normal, cleaning the oil
hydraulic unit
when changing oil.
gantry
1 gantry hydraulic system should normal, cleaning the oil
when changing oil.
Apply the brake several times, watch
the stabilization. Check content in
of bush and brake disc; 2. disc
2 wheel brake
temperature should below
and brake sounds should be normal
no abnormal sound and glowing,
3 gear boxes cleaning the box and filters when
changing gear oil
reducer 10%-15% of the rated load,
low speed running for at least 50
4 gantry motor
hours, smoothy accelerate and brake.
No emergency brake.
5 gantry emergency stop no abnormal sounds and glowing.
The "result" column should be filled in :[√]pass；[O]fix/change；[×]rejected. The checking sheet should
be collected after finish.
2- 36
manual
Table 2-20: mobile maintenance task list

technical
serviced by： date：
confirmed by：
whole crane
keep all functions in
1 communication system
good condition
checking the walkway
lighting, spot light
and aviation alarm
2 lighting
light. Make sure the
function of the
aviation alarm light.
checking the smoothly
running of the
3 elevator elevator, make sure the
elevator stop at the
correct floor.
air conditioner (machinery house and checkin the function of
4
driver cab) the air conditioner
checking the emergency
5 emergency stop
stop function
machinery house
well lubricated, no
loosing for the press
wire rope of three main parts (visual
1 plate, reliable
inspection)
colligation for the
redundant rope.
keep reliable function,
no loosing,distortion;
keep correct clearance
of the brake disc; no
abnoamal
2 brakes
abrasion ,cracks; keep
polished surface and
qualified brake toque.
checking the compensate
stroke.
2- 37
manual
no leakage for the pipe

and valve manifold,
reading from the gauge
should normal, cleaning
the oil reservior,
3 hydraulic system filter and other valves
when changing oil.
Checking the
temperature rising
abnormal sounds of the
unit.
keep in good
drums of three main parts, high and low
4 condition(visual
speed coupling.
inspection)
keep in good condition,
no loosing bolts and
keep limit switch
5 bearing base
mounted on correct
location.(visual
inspection)
keep gear oil at normal
level, no abnormal
6 gear boxs of three main parts
sounds,glow and
leakage.
emergency stop for electric boom and
7 keep in good condition
machinery house
make sure no logic
short-circuit or
constraint. Checking
the noise and smell of
8 electric boom the control
panel;chekcing the CMS
daily.inspect the
electric current and
voltage from CMS and PQM
checking the noise and
vibration for motor,
9 noise and vibration
gear box, brake, drum,
coupling and bearing
keep motors and fans in
10 motors for three main parts
good condition
keep no broken for the
gates and windows for the machinery
11 doors and windows, shut
house
them off after working.
boom
no twist for the wire
rope, cable and
1 festoon elastic, no abnormal
sound when the festoon
running.
2- 38
manual
no abnormal abrasion
for all rollers on the
trolley, rotate freely.
2 trolley
Keep the wheel and level
wheel in good conidtion
without noise.
checking the wire rope
for main hoist and
3 wire rope
trolley is at correct
location.
no aging, loosing;no
4 boom damper distortion and crack
for the limit plate
no distortion, loosing
blots,and bolts no
5 slap block for boom support
mssing.(visual
inspection)
and valve manifold,
the oil reservior,
6 multi-function hydraulic system filter and other valves
when changing oil.
Checking the
temperature rising
unit.
No leakage for
connector, correct
7 trolley and catenary tension cylinder location for limit
switchs. No inner
leakage for cylinders.
No distortion, loosing
and rotate freely for
sheaves on the tip of
8 sheave
boom and girder,
sheaves for the trolley
and for the boom.
9 roller at joints(visual inspection) no abnormal abrasion
No loosing, abrasion
and separating for
pressure plate and
bolts on trolley rail.
No impact on the rial
10 trolley rail(visual inspection) connectors when the
trolley drive throuth.
No crack, tip-off ,
loosing for the connect
plate and locate block
on the short rail.
2- 39
manual
clamp plate for hoist wire rope at the no loosing and

11
end of the boom distortion
checking the
12 anti-bumping limit switch anti-bumping wire rope
at the two side of boom
checking the location
the sheavs on tensioner and anti-snag of the sheavs on
13
device tensioner and anti-snag
device
make sure the cable in
the groove , checking
14 spreader cable reel the noise and vibration
for the motor and speed
reducer.
top platform
no distortion, crack,
1 limit switch plate make sure the contract
checking
of limit switch
after
well wiring and no
2 "boom
limit switch loosing bolts
up"
no noise, abrasion,
3 sheaves and bearings for boom
distortion and loosing.
driver cap
for trolley:speed,
acceleration, AI speed
reduce,stop and cable
festoon system. For
boom and hoist: speed,
accerelation speed
reduce when up/down and
stop;checkign the low
1 control desk
speed hoist in ship
clapboard. checking the
lighting function in
driver cab; checking
the spreader guide and
pin; checking the
function of joystick
and control panel
checking the function
of air conditioner, air
2 air conditioner electric system filter, lighting,
defrost device and
windshield wiper
checking the function
3 chair of seat and shoulder
safety belts.
clean the grease and
4 gate and window dust, shut windows and
doors off after using.
gantry cable reel
2- 40
manual
no missing, loosing,
distortion for bolts on
the reel; no abrasion
1 gantry cable reel for cable and reliable
motion for the
reel.(visual
inspection)
normal oil level, no
2 speed reducer for gantry cable reel
leakage and vibration
gantry
and valve manifold,
the oil reservior,
1 gantry hydraulic system filter and other valves
when changing oil.
Checking the
temperature rising
unit.
no leakage and well
2 brake and pipe fixed pipe, good brake
function
no distortion, leakage
3 damper
and broken
correct position and
4 rail cleaner
nodistortion
no loosing and abnormal
5 cable roller and guide abrasion; no block for
guide springs
normal oil level, no
6 speed reducer
leakage
check the obstacle on
7 rail the rail or broken for
of the rail
check the obstacle on
the groove of high
8 high voltage cable groove
voltage cable or broken
for of the groove
check the speed and
9 motor
acceleration
keep function in a good
10 emergency stop
condition
apply the stowage after
11 stowage device
working
spreader
2- 41
manual
check the spreader

guide and pins,
checking the drive
chain's safety and
tension;checking the
position of 20,40 45
1 spreader feet; checking the
level and positive
position of spreader;
checking the gear oil in
extend gear box;
checking the connection
of the cable plug.
\checking the assembly
and function of limit
2 headblock
switchs for hoist wire
rope loosing
The "result" column should be filled in :[√]pass；[O]fix/change；[×]rejected. The checking
sheet should be collected after finish.
2- 42
manual
Table 2-21 scheduled maintenance task list (weekly)

technical
serviced by： date： confirmed
by：
whole crane
check the function of all working spot
1 lighting
lights
check the cable connection and bolts'
1 limit switch
fastening
machinery house
wire rope of three main well lubricated, no loosing for the press
1 parts (visual plate, reliable colligation for the
inspection) redundant rope.
Checking the
boom brakes
and gear box
keep reliable function, no during "boom"
loosing,distortion; keep correct motion;cooper
clearance of the brake disc; no abnoamal ate with
2 brakes
abrasion ,cracks; keep polished surface driver when
and qualified brake toque. checking the checking
compensate stroke. hoist brakes
and trolley
high speed
brakes.
manifold, reading from the gauge should
normal, cleaning the oil reservior,
3 hydraulic system filter and other valves when changing
oil. Checking the temperature rising
abnormal sounds of the unit;checking the
filter pressure gauge
no crrack,abnormal abrasion and loosing

drums of three main
of bearing base; no noise and vibration
4 parts, high and low
for bearing; no tip-off for lock block;
speed coupling.
reliable rope pressure plate.
keep in good condition, no loosing bolts

5 bearing base and keep limit switch mounted on correct
location.(visual inspection)
gear boxs of three main keep gear oil at normal level, no abnormal
6
parts sounds,glow and leakage.
high speed coupling for
7 no abnormal sound and loosing bolts
three main parts
2- 43
manual
low speed coupling for

8 no abnormal sound and leakage
three main parts
limit device on the tip no loosing and abrasion of encode
9
of the bearing base. coupling
keep in good condition; well lubricated;
10 service bridge crane no loosing of pressure plate; keep wire
rope in good condition.
make sure the aeration and fan working
11 electric cabinet
condition
girder
all wear block fixed; no distortion,
1 anti-snag platform
loosing or abnormal abrasion for sheaves.

anti-snag hydraulic normal, cleaning the oil reservior,
2
system filter and other valves when changing
abnormal sounds of the unit.
3 joints well lubricated and no abnormal abrasion

wire rope tension No leakage for connector, correct
4
hydraulic system location for limit switchs.
fixing bolts for tension
5 no loosing and broken
sheaves
No leakage for connector, correct
trolley tension
6 location for limit switchs. No inner
cylinders
leakage for cylinders.
cable festoon
runing wheel and level no droping, distortion, abnormal
1
wheel abrasion; no decline when running
2 rail well lubricated
3 fixing bolts ang screw no loosing; no screw broken.
damper and pressure
4
rubber no loosing,aging, distortion and crack
5 elastic and wire rope
no broken, droping, aging; free rope tip
no missing, loosing, distortion and
6 cable clamper
broken; no broken for cable
rubber protector for
7 no moving, abrsion and missing
lanside tip cable
driver cab and trolley top
trolley festoon
1 no distortion, loosing
tractor
。Cleaning chair, slide freely and
reliable fixing; gate for walkway and
2 driver cab diving platform opens freely, the
clearance for gate with locking plate is
normal and no blocking.
2- 44
manual
no distortion, loosing and abnormal

3 sheaves
abrasion
4 wire rope pressure plate no distortion and loosing
roller on the trolley no abnormal abrasion,loosing; rotate
5
top freely
speed reducer for well fastened , enough oil; no noise and
6
spreader cable reel glowing; checking the chain
rolling parts for well fastened and normal distance, no
7
spreader cable reel abnormal abrasion ofor cable
no abnormal abrsion; the level wheel not
trolley wheel and level touch the rail bolts; no loosing bolts for
8
wheel cover; well lubricated and no abnormal
condition for wheel bearing.
9 trolley damper no distortion, leakage and broken
well lubricated wire rope with no broken

section. when wire rope diameter is 7%
less than nonimal diameter, even no
broken wire found.2.when 10% of the ires
are broken in this bundle.No loosing,
abrasion and separating for pressure
plate and bolts on trolley rail. No impact
10 linkage with trolley on the rial connectors when the trolley
drive throuth. No crack, tip-off ,
loosing for the connect plate and locate
block on the short rail.no losoing or
droping wear block under the machinery
house and boom. no abnormal abrasion for
the boom joint's roller, and the roller
rotate freely.
limit switch for hoist corect contract, reliable connection for

11
gravity block limit switch. No loosing bolts
boom
boom sheaves and no abnormal abrasion,loosing; reliable
1
bearings at boom sheave function
2 anti-bumping wire rope normal tension and no broken
joints between boom and no abnormal sound and abrasion. Well
4
girder lubricated bearing and fastened bolts
no abnormal abrasion,loosing; rotate
5 roller for joints
freely
6 boom buffer no loosing,aging, distortion and crack
boom stay bar fasten the bolts lubricate the pin
wire block for boom stay no distortion; no loosing and missing of
7
bar support bolts.
8 wear block for wire rope well fixed and no abnormal abrasion
2- 45
manual
no abnormal abrasion,loosing; rotate

9 fixed roller
freely; well fixed wear block
no distortion for fiexed sheaves at tips
of boom and girder, and sheaves on the
8 sheaves
top of trolley; good condition for sheave
shafts, well lubricated bearing
boom tip
clamp plate for hoist
1 no loosing and distortion
wire rope
2 wear block and bolts well fastened
no loosing, distortion and abnormal
3 trolley sheave
abrasion
top platform
no distortion, crack; good contrct with
1 hook limit plate
limit switch
rope-loosing limit
2
switch shaft well lubricated, sensitive and reliable
sheaves and bearing for no noise, abrasion, distortion and
3 checking when
boom part loosing
"boom up"
clamp plate and base for
4 no loosing, distortion and crack
rope broken protection
stay bar connect plate
no distortion, tip-off, loosing and
5 and bolts for lock
abrasion
plate
gantry cable reel
no missing, loosing, distortion for
bolts on the reel; no abrasion for cable
1 gantry cable reel
and reliable motion for the reel.(visual
inspection)
speed reducer for gantry normal oil level, no leakage and
2
cable reel vibration
gantry
normal, cleaning the oil reservior,
1 gantry hydraulic system
filter and other valves when changing
abnormal sounds of the unit.
no leakage and well fixed pipe, good brake
2 brake and pipe
function
no grease, normal abrasion;no loosing
3 disc of wheel brake
bolts
coupling no loosing and abnormal bolts
4 damper no distortion, leakage and broken
no distortion, rust; good support and
5 steel boots
chain
2- 46
manual
no distortion and tip-off, well

6 stowage device
lubricated, sensitive and reliable
7 rail cleaner correct position and nodistortion
no loosing and abnormal abrasion; no
8 cable roller and guide
block for guide springs
9 speed reducer normal oil level, no leakage
spreader and headblocks
1 hydraulic unit hydraulic pressure should be 11Mpa
no leakage; reliable fixed and enough
2 hydraulic oil reservior
oil;
checking the bolts at damper, speed
3 bolts
reducer base and guide motor
checking the lubrication for drive
4 lubrication reducer, extend chain, bearing and lock
pin
clean and fasten the sn=ensor and limit
5 cleaning
switch
make sure the limit switch function for
connection between separating or connecting the spreadr and
6
spreader anf headblock headblock
junction box and control checking the cable connecting and

7
desk on the headblock fastening of the bolts
well lubricated for lock pin and other
8 over-height adapter
moving parts.
The "result" column should be filled in :[√]pass；[O]fix/change；[×]rejected. The checking sheet
should be collected after finish.
2- 47
manual
Table 2-22 scheduled maintenance task list (bi-weekly)
Equipment No.： srart time： no. of checking sheet：

checked by： finish time： running hours：
technical
service： date： confirmed
by：
no. checking part content result process
whole crane
brakes for three main parts cleaning the brake disc; checking the
1
in machinery house abrasion of bush for the brakes
anti-bumping device for checking the position for anti-bumping
2
boom wire rope and its limit switch
3 steel structure no abnormal broken
cleaning the brake disc; checking the
4 gantry wheel brake
abrasion of bush for the brakes
spreader
1 motor and coupling good condition; no vibration and noise
2 gear box good condition; no vibration and noise
reliable function; no noise,leakage and

3 telescope motoe
loosing; enough oil
4 hydraulic pump and valves
loosing
hydraulic piping and reliable function; no noise,leakage and
5
connector distortion
all cylinders(extention,
6 rotate lock, middle lock,
loosing; well lubricated
hook)
well fixed; no leakage and loosing;
7 oil reservior
enough oil
8 filter no leakage and correct display
reliable function, no distortion,crack

9 rotate locking device
for bush. No loosing bolts
10 container landing lock
distortion
reliable function, no distortion,crack
11 guide board
for bush. No loosing bolts
reliable function, no distortion,crack for bush.
12 drive chain and tank chain No loosing bolts; keep the tention length for
driving chain is 25mm(40 feet)
middle lock slip slot(up and
13 well lubricated; no abnormal abrasion
down,left and right)
14 telescope beam well lubricated; no abnormal abrasion
2- 48
manual
main structure and parts no distortio, tip-off, crack; no crack

15
structure on the lock pin hole
16 tip back-rotate wheel well lubricated and reliable function
wear block for guide and
17 no abnormal abrasion and loosing
telescope beam
18 bolts fastenning spreader guide motor and gaer box base
the sheaves, bearing and no noise. Abrasion, distortion and
19
fastening for head block loosing
steel structure for head
20 no distortio, tip-off, crack;
block
reliable function, no distortion,crack for bush.
rotate locking device for
21 No loosing bolts; keep the tention length for
head block driving chain is 25mm(40 feet)
22 portable bar and pin shaft well lubricated; no abnormal abrasion

well lubricated; no abnormal abrasion; no
23 spreader cable reel distortion for spring and no crack for
bearings
24 dooa for head block neatly motion and lock plate
protect cover for sheaves
25 no distortion, tip-off and crack
on head block
electric parts for spreader
26 ternimal junction box well fixed
power box and fasst connect
27 well fixed and no broken
plug
28 terminal box on head block well connected, no broken and inleakage
middle lock limit
good condition, well connected
switch
middle lock
position limit good condition, well connected
switch
open lock limit
switch
close lock limit
switch
container
limit
29 landing limit good condition, well connected
switch
switch
middle lock limit
switch
20FT limit
switch
40FT limit switch good condition, well connected
45FT limit switch good condition, well connected

twin container
good conditon; well fixed and sealed
limit switch
2- 49
manual
middle lock hook

permitting limit good condition, well connected
switch
general valve good condition and no leakage
guide up and down good condition
telescoping good condition

sloenoid
30 valve open and close
good condition
plug locking
middle lock (up
good condition
and down)
middle
good condition
lock( telescope)
limit switch connecting
plate
power box and fast connect
plug
33 terminal box for head block well connected, no broken and inleakage
2- 50
manual
Table 2-23 scheduled maintenance task list (monthly)

technical
by：
elevator and LS support beam
1 boom operating house clean and no dust
switches and limit checking function for all the emergency
2
switches stop switches and limit switches.
lubrication for the checking the lubrication for all moving
3
elevator parts
normal running and no noise; no loosing
4 speed reducer and motors
bolts
5 control system keep normal working
bolts of the pressure plate
cover for anti-snag sheave
suppot beam and its no distortion, crack, loosing bolts and
7
accessory noise when running
clean the brake disc, checking the
8 brake
abrasion of brake bush
9 cable checking the twist and abnormal abrasion.
nachinery house
1 cleaning no grease and dust
bolts for motors, brakes,
2 couplings and bearing base no loosing and distortion
of the main parts
wire rope clamper for three
3
main parts
gear box for three main keep gear oil at normal level, no abnormal
4
parts sounds,glow and leakage.
keep reliable function, no
loosing,distortion; keep correct
emergency brake for three clearance of the brake disc; no abnoamal
5
main parts abrasion ,cracks; keep polished surface
and qualified brake toque. checking the
compensate stroke.
high speed brakes for three keep in good condition; no broken for the
6
main parts structure; correct brake torque.
good working condition; no abnormal
7 motors for three main parts
temperature; good aeration
8 lighting good working condition
9 fan good working and no noise
checking the abrasion, broken, lubrication for
the wire rope; checking the hood abrasion,
10 service bridge crane
fastening the bolts; checking the running for
cable trolley and cable.
2- 51
manual
checking the "fuse" and "shut-off;

11 electric cabinet checking the contract for relay and
contactor
girder
oil nipple and lubrication
1 no leakage, distortion and rust
piping
main structure for
anti-snag device
3 joints well lubricated, no abnormal abrasion
bolts for prssure plate
cover of the anti-snag
oil nipple and lubrication
piping for tension device
fixing bolts for tensioner
sheaves
main structure for tension
7 no dsitortion, tip-off and crack
device
8 wear blocks well fixed, no abnormal abrasion
no distortion, tip-off and loosing,
9 outdoor service crane
correct position fo sliding trolley
cable festoon
1 cable no broken
structure for testeeon
2 no distortion, crack and tip-off
trolley
running wheel and level no droping, distortion, abnormal
3
wheel abrasion; no decline when running
4 rail well lubricated
5 bolts and screws no loosing; no screw broken.
6 damper
no loosing,aging, distortion and crack
7 elastic and wire rope no broken, droping, aging; free rope tip
no missing, loosing, distortion and
8 cable clamper
broken; no broken for cable
boom
bolts and pressure plate
1 no loosing, droping and abrasion
for the rail
connect plate and located
2 no crack, tip-off and loosing
block for short rail
the joint part of rail for no sunken area,the difference for level
3
boom abnd girder is normal
no sunken area, crack and abnormal
4 rail for boom and girder
abrasion
furcation, guide wheel and well lubricated; no abrasion, loosing and
5
slide rail correct psition for guide wheel
no tip-off, distortion, leakage of rain,
6 boom operating house good locking for the door; the lighting
and switches is in good condition.
2- 52
manual
7 lubrication piping no leakage, rust and distortion

boom sheaves and bearings
8 no abrasion, distortion and loosing
for boom and girder
no distortion, tip-off, crack; well
9 bearing base
lubricated and no abnormal abrasion
10 boom damper no distortion, leakage and broken
joints shafts and their no abrasion, distortion and loosing and
12
fastening well lubricated
13 joint base and shear block no sliding, crack and loosing bolts
14 roller rotate freely and normal abrasion
lubrication piping and
15 no leakage, rust and distortion
nipples on joint upper beam
no leakage, rust and distortion; good
16 air piping and reduce vlave
valve
normal tension, no broken; good limit
17 anti-bumping wire rope
switch
18 wear block under beams no abnoraml abrasion
sheaves at ends and its
20 no abrasion, distortion and loosing
fastenning
limit switch for trolley good function; connected cable and no
21
running loosing bolts
wire rope for trolley and checking the abrasion and broken for the
22
main hoist wire rope; lubricate the wire rope
guide wheel for rope no abnormal abrasion, distortion and
23
changing loosing
boom tip
clamp plate for hoist wire
1 no loosing and distortion
rope
no loosing, distortion and abnormal
2 trolley sheave
abrasion
top platform
connect plate shaft for
1 front stay bar abnd the no abnormal abrasion and noise
copper bush
shaft for front stay bar
2 no abnormal abrasion and noise
abnd the copper bush
no abnormal abrasion, noise, distortion
3 boom sheaves and bearings
and loosing
4 rope loosing device sensitive and distortion
rope broken protect plate
5 no crack, distortion and loosing
and its base
no leakage, rust and distortion; good
6 air piping and reduce vlave
valve
7 lifting trolley senitive, no distortion and loosing
bolts for connect plate
no abnormal abrasion, tip-off, distortion
8 shaft for front stay bar
and loosing
and lock plate
2- 53
manual
top lubrication piping and

nipples for boom
front and back top stay no abnormal abrasion, tip-off, distortion
10
bar and joint base plate and loosing
no abnormal abrasion, distortion and
11 sheaves bse for boom
loosing
checking the abrasion and broken; well
12 boom wire rope
lubricated
make vane, cable connecting and function
13 wind speed meter
in good condition
good function, well connecting and no
14 boom limit switches
loosing bolts
no abnormal abrasion, noise, distortion
15 structure for boom stowage
and loosing
lubrication piping and

1 no leakage, rust and distortion
nipples
2 upper limit switch
loosing bolts
no distortion, loosing and abnormal
3 sheaves
abrasion
4 wire rope pressure plate no distortion and loosing
roller and wear block on no abnormal abrasion,loosing; rotate
5
the trolley top freely
trolley wheel base and its no abnormal abrasion, tip-off, distortion
6
fastening and loosing
speed reducer for spreader well fastened , enough oil; no noise and
7
cable reel glowing; checking the chain
rolling parts for spreader well fastened and normal distance, no
8
cable reel abnormal abrasion ofor cable
no abnormal abrsion; the level wheel not
trolley wheel and level touch the rail bolts; no loosing bolts for
9
wheel cover; well lubricated and no abnormal
condition for wheel bearing.
no abnormal abrasion, tip-off, distortion
10 structure
and loosing
no droping and broken, locker and seal is
12 window and door for the cab
in good condition
doors for the cab and
13 open freely, no block for lock plate
diving platform
14 control desk in the cab good working for pushbuttons and joystick
roller and wear block on no abnormal abrasion and loosing; no
15
the trolley top tip-off for the base
16 trolley festoon tractor no distortion, loosing
enough gear oil, no leakage, loosing
17 cable reel
bolts; no abrasion for cable
2- 54
manual
gantry
1 motors good working and no noise
gear box for three main enough gear oil, no leakage, loosing
2
parts bolts; no abrasion for cable
3 stowage limit switches
loosing bolts
no crack and broken for rai and base;

cleaning the rail slot and stowage hole;
no broken and loosing for gantry block.
4 dock basing
Checking the rail: linear, distance,
level difference, sunken, clearance,
wrong connection and slope
spreader, headblock and over-height adapter

no abnormal abrasion,no crack for welding
1 mainstructure
line
2 connecting bolts no loosing
upper rope-loosing limit good function, well connecting and no
3
switch for head block loosing bolts
2- 55
manual
Table 2-24 scheduled maintenance task list (quarterly)

technical
by：
whoel crane
no abnormal abrsion; fragment or
1 motor
nicks.good condition for cooler
good condition for contractor, relay and
2 electric cabinet
switches
3 air conditioner good condition
4 cable no broken ,checking with mega olm-meter
good condition, well connected and no
5 limit switches
loosing bolts
6 hydraulic system no leakage for connectora
no grease for brake disc, no abnormal
7 brake
abrasion for brake bush
8 geaer box no noise, abnormal temperature, leakage
bearing for sheaves,wheel, nearing base
9 lubrication and joints; shafts for star bar pin and
trolley pin
checking the bolts connecting and
10 coupling
elastic parts' abrasion
11 drum and sheaves no abrasion for groove
crane main structure; stair and platform
structure for stair,
1 no tip-off, distortion and rust
platform and handrail
stair footplate and
2 no distortion and loosing
fastenning
grating plate and fasten
3 no distortion, moving and loosing
hook
4 main structure no tip-off, distortion and rust
5 painting no rust, cockle and big area of peel-off
6 high strength bolts no loosing and rust
welding line for girder
7 and upper beam (seaside and no tip-off and crack
landside)
8 front and back stay bar no distortion, crack; reliable function
9 level stay bar no distortion, crack; reliable function
diagonal support of portal
10 no distortion, crack; reliable function
frame
no tip-off, distortion, rust and
11 limit switch bumping plate
abrasion
2- 56
manual

12 steel structure for gantry
abrasion
shaft lock plate and
no tip-off and loosing for bolts of shaft
13 anti-cut block for
block
equalizer shaft
no tip-off,distorion, leakage and good
14 check room
lock
15 air piping and reduce valve no leakage, distorion, rust; good valve
16 anti-wind bar and cable neatly motion, well lubricated and fixed
17 air compress system good condition; no leakage
18 emergency device well fixed, no broken and leakage
emergency transmission
19 no abrsio
chain
20 rope changer
abrasion
main structure for
21 no distortion, tip-off and leakage
machinery house
portal beam and rail for no tip-off, distortion, rust and
22
service crane abrasion
pressure plate for
23 no twist bolts and normal torque
trolley rail
boom joint
abrasion
wheels for gantry and
24 no abrasion
trolley
block for trolley no loosing and broken
hoist motor and brake for good condition; no rust and block for
25
indoor service crane brake
26 rope guide and rope changer good condition, no slope bolts
27 damper no aging, crack and loosing
main structure for
anti-sang
no distortion, tip-off and loosing; good
29 outdoor lifting crane
position for trolley
30 structure for testoon
abrasion
31 structure for cab hanging
abrasion
32 hanging bolts for cab
abrasion
steel structure for the
33 no distortion,tip-off and inleakage
cab
structure for trolley no tip-off, distortion, rust and
34
frame abrasion
35 support base for sheaves
abrasion
2- 57
manual
main structure for tension no tip-off, distortion, rust and

36
device abrasion
37 outdoor lifting trolley neatly; no distortion and loosig parting
support base for boom no tip-off, distortion, rust and
38
sheaves abrasion
steel structure for boo no tip-off, distortion, rust and
39
stowage abrasion
well lubricated, good condition for
40 spreader sheaves and bearing; no crack for welding
line
2- 58
manual
Table 2-25 scheduled maintenance task list (semi-annually)

technical
by：
general and elevator
keep reliable state for light base and
1 lighting rectifier, good condition for emergency
lighting
coennection for limit switches;
2 limit switch
fastenning for bolts
3 gear box for elevator good condition, no noise and enough oil
4 standard joint no distorion and crack, no loosing bolts
handrail,damper and good condition, no distortion
5
elevator door andabnormal abrasion
the corect and safety no noise and abrasion for guide wheel;
6
function for elevator correct stopping
he motor and electric clean the radiater of motor, checking the
7
system for elevator cable, connection and sealing
alarm, lighting and
8 communication system for good condition
elevator
machinery house
clean the motor coil, checking the motor
1 motor
resistance by mega-ohm meter
checking the connection for contactor and
electric cabinet relay; checking the resistance and
capacitnce for reactor and filter.
checking the limit switch function,
2 brakes checking the abrasion and broken for the
parts
lubricate the coupling, checking the
3 rope changer
abrasion
no noise and abnormal temperature for
5 bearing base bearing, checking the fasten for bolts,
well sealed
6 gear box well fixed and no leakage; enough oil
10 service crane well connected
back girder
1 outdoor beam crane lubricate the bearing
sheaves for tensioner and
2 lubricate the bearing
anti-snag
3 trolley tensioner cylinder lubricate the bearing
cable festoon
2- 59
manual
no crack for welding line; no distortion

1 rail
for rail and hanging part
2 fixing bolts and screws no broken and distortion
spped and acceleration
1 good condition
for trolley and main hoist
clean; checking the connectionof bolt,
slip ring box for cable
2 checking the abrasion of carbon brush;
reel
checking the sealing of box
3 brake for cable reel good condition
boom
joints between boom and
1 no abnormal abrasion and noise
girder
2 roller for the joints no abnormal abrasion, rotate freely
3 trolley damper No distortion and broken
4 weight sensor well connected and no broken cable
top platform
1 wind speed alarm good condition and corect display
lubricate the bearing, checking broken
2
beam crane state
gantry
1 speed and acceleration good condition
clean the motor coil, checking the motor
2 motor
resistance by mega-ohm meter
lubricate the coupling, checking the
3 coupling
abrasion
spreader and head block
1 oil reservior engough oil
2 filter good condition and corect display
3 lock pin no abnormal abrasion
4 over-height adapter well lubricated
2- 60
manual
Table 2-26 scheduled maintenance task list (annualy)

technical
by：
general
crane and accessory （like certificate every year
1
air compresser）
checking the broken for limit
switches, cable, ray cable, terminal,
2 electric
cable number, cable groove and cable
guide; clean the connector for ray cable
checking the communication system, chagn
3 electric
the power for the emergency lights
make sure the fixing for ternimal box, control
4 electric panel and I/O equipment and control desk. No
broken for cables
lubricate the knife switch; checking the
function for indicator light, switch
pushbutton and gauges. No broken cable,
5 electric cabinet dust on risistance and
over-heat.checking the setting for over
heat; over-current and time relay.
checking the insulation for reactance.
checkingt the abnormal state for
printing board and electric parts,
6 electric parts
checking the weight sensor through
standard load.
checking no dust in the air; checking the
transformer(main, light,
7 transformer
control)checking the connection for
cable connector
no fire tract for electric reactance,
reactance clean the parts, no broken. Good function
for cooler.
keep clean, fan, lights and temperature
electric
alarm in good condition
8 service crane certificate every year
certifacate every year, exhaustively
9 elevator checking the abrasion for loading
bearings and other parts under load.
air conditioner ( electric good condition
10
boom and driver cab)
machinery house
well cable connected, good condition for
1 motors the rectifier, adjusting the current
through the rated value on the nameplate
2- 61
manual
checking the abrasion for brake bush, and

2 brakes decline abrasion; no distortion and crack
for brake structure
checking the quality of hydraulic
3 hydraulic system
oil( hydrous rate)
checking the abrasion for drum rope

4 drums
groove
checking the limit switch, lubricate the

5 emergency device
chain and coupling
checking the torque for base fixing
gear boxes, motors and
6 bolts , checking the joggle for the gear
brakes for three main parts
inside
checking the abrasion and centralization
7 low speed couplings
for the coupling; fasten the bolts
8 fhigh speed couplings checking radius and angle
the limit device on the tip checking the abrasion and centralization
9
of bearing base for the limit switch coupling
checking the rope guide, safety device,
control cable, control panel, brake and
hanging device for wire rope stowage.
fasten all the bolts, checking the crack
10 service crane on the hook;checking the cold distortion,
abnormal abrasion fixing for base and
hook, emergency limit switches and
coupling for low speed hoist. lubricate
the wire rope
back girder
main structure for
1 no crack on welding line
anti-snag
2 hydraulic system correct pressure setting for the valves
sheaves for tension and
3 checking the press track on rope groove
anti-snag device
cylinders for tension and
4
anti-snag device no leakage and broken
lubricate the bearing, checking the
1 spreader cable reel
joggle for gear
wheels and horizontal

2 no abnormal abrasion
wheel for trolley
no abnormal abrasion, rotate freely; well
3 fixed roller fixed wear block and no crack on the
roller base.
top platform
1 boom wire rope well lubricated ,checking the abnormal checking
2- 62
manual
abrasion and broken when"boom"

gantry cable reel
lubricate the bearing, checking the
1 gantry cable reel
joggle for gear
well sealed for the box, no inleakage;
high voltage slip ring box good contraction for slip ring and carbon
brush; no broken and loosing.
gantry
clean the box; no distortion, leakage and
ground terminal box
broken, well cable connection
mobile high voltage cable no distortion and broken
1 wheel brake disc checking the abrasion of brake bush

lubricate wheel bearings and pin shaft of
2 lurication
equalizer
checking the quality of gear oil( hydrous
3 gantry gear box
rate)
checking the quality of hydraulic
4 hydraulic system
oil( hydrous rate)
1 lubrication lubricate the motor and bearings
spreader, head block and checkign the abrasion for the lock pin
2
over-height adapter
2- 63
manual
Table 2-27 scheduled maintenance task list (every 5 years)

technical
by：
whole crane
1 QC and accessory certified every 5 years
exhaustively check the motors, brakes and
2 elevator gears in gear box, change all the safety
equipment
machinery house
motors for three main
1 changing the cooler and vane
parts
gear box for three main exhaustively check the gear and gear
2
parts joggle.
3 exhaustively checking and heavy repair
three main parts
three main parts
high speed brake for three
main parts
low speed brake for three
main parts
7 service crane certified every 5 years
1 cable exhaustively checking and no broken
speed reducer for spreader exhaustively checking the gear interface
2
cable reel and gear joggle
exhaustively checking the abrasion for
3 wheels for trolley
wheels
4 cables for trolley festoon exhaustively checking and no broken
cable reel
exhaustively checking the gear interface
1 gear box for cable reel
and gear joggle
gantry
1 wheels
wheels
2 wheel brake exhaustively checking and heavy repair
exhaustively checking the gear interface
3 gear box
and gear joggle
1 lock pin
wheels; no crack
2- 64
manual
Table 2-28 scheduled maintenance task list (every 10 years)

technical
serviced by： date：
confirmed by：
whole crane
1 QC and accessory certified every 5 years
exhaustively check the motors, brakes and
2 elevator gears in gear box, change all the safety
equipment
machinery house
1 motors for three main parts exhaustively checking
2 gear box for three main parts exhaustively checking
3 exhaustively checking
three main parts
three main parts
high speed brake for three
main parts
low speed brake for three
main parts
7 cooler and emergency motor exhaustively checking
main switch for high
voltage cabinet
girder
sheaves for tensioner and
anti-snag device
cable festoon
1 cable for festoon trolley exhaustively checking
1 sheaves exhaustively checking
2 slip ring box exhaustively checking
3 cable for spreader exhaustively checking
4 trolley wheel exhaustively checking
boom tip
1 trolley wheel exhaustively checking
gantry cable reel
1 cable exhaustively checking
2 high voltage slip ring box exhaustively checking
gantry
1 gear box exhaustively checking
2 wheel brake exhaustively checking
3 cable exhaustively checking
spreader and headblock
1 spreader and headblock exhaustively checking
2- 65
Shanghai Zhen hua Quayside Container Crane
Chapter THREE
Heavy Industries Co.,Ltd. Configuration and Maintenance Manual
Chapter 3 Some important parts replacement
3.1 General:
3.1.1 Attention
This chapter includes main components such as：bearing

pedestal、motor coupling、drum coupling、motor brake、
drum brake、gantry wheel brake、trolley wheel、gantry
wheel 、main hoist sheave、rope idler roller and so on. The
personnel who takes part in the replacement procedure
Danger of tripping!
must be acquainted with the structure of components.，
control the operation step and have an ability of coping
with the abrupt affairs. Before working, it is obligatory that Keep away from suspended loads!
set down the ethnics in detail according to this chapter,
have a pre-work meeting, adopt to safety precautions， Pinch Hazard!
point someone who takes responsible for safe coordination,
and strictly obeys the safety rule request in chapter 2.
3.2 Bearing pedestal replacement

3.2.1 Preparation
The bearing pedestals are included in main hoist

mechanism, trolley driven mechanism, boom hoist
mechanism, which are all level form.，shown in figure 3-1.
Before replacement, carefully research the drawings,
understand the bearings constitutes，the drawings about
bearing pedestal on table 3-1. personnel and tools on table
3-2.
Table 3-1: Drawings for bearing pedestal
replacement
Main hoist bearing
J607A0300，HDS03a-800 figure 3-1：bearing pedestal appearance
pedestal
J607A0400 ,
Trolley bearing pedestal
ZM006500-J474B04
Boom hoist bearing
J607A0500，HDS03a-800
pedestal
Table 3-2 ： personnel and tools for bearing
pedestal replacement
Personnel/quantity Tools/quantity
Lifting worker 3 Bottle gourd 1(10t)
welder 1 larma 1
fitter 1 Tension wrench 2
electrician 1 others several
1 2 3 4 5 6 7 8
figure 3-2：bearing pedestal sketch map
1 end over1 2 seal 3 double screw bolt 4 upper seat
5 down seat 6 bearing 7 L.S shaft 8 end cover2
3-1
Chapter THREE
3.2.2 Replacement procedure
1) Lower the spreader to the ground and slacken the

Main Hoist ropes. (or position the boom to the
level and slacken the Boom Hoist ropes)
2) Lock out the crane’s motion for the affected drives
by performing lock-out and tag-out procedure.
3) Disconnect the coupling between the drum and the
rotary limit switch, Use slings and softeners to
connect the drum to the service crane.
figure 3-6：Step 8
4) Tie off each of the ropes in machinery house to
remove the rope load from the drum. 8) Remove the L.S shaft or shaft end plate.
Slacken enough rope, so that the drum can be moved

slightly. Before replacement the whole appearance of
mechanism are shown in figure3-3
figure 3-7：Step 9
figure 3-3：The whole appearance of mechanism

before replacement
5) Remove the bearing pedestal end cover nuts.
figure 3-8：Step 9
The drum end is fasten on the

support in machine house by
ropes. Lift the drum up 50mm by
bottle gourd, then move the lower
figure 3-4：Step 6 bearing pedestal sideways from
6) Unfasten the stud nuts and screw. the drum shaft by the service
crane，use a puller with a 10-ton
capacity to pull out of the bearing.
9) Carry the bearing pedestal to the ground by the

service crane, other procedure will do at workshop.
figure 3-5：Step 7
7) Remove the bearing pedestal end cover 1
3-2
Chapter THREE
figure 3-9：Step 10 figure 3-13：Step 13

13) Re-assemble the bearing pedestal together in the
reverse order mentioned above.
14) Realign the drum couplings. Refer to chapter 2 for
alignment criteria. Verify the drum-mounted rotary
limit switch setting and alignment.
15) Remove lock-out and tag-out devices and Pre-Op
the crane. Startup and monitor the crane to verify
its operation before returning it to service.
figure 3-10：Appearance after up pedestal
3.3 Motor coupling replacement
removed
10) Remove the bearing and end cover 2. 3.3.1 Preparation
The motor couplings are included in main hoist

mechanism, trolley driven mechanism, boom hoist
mechanism ， which are all flexible elastomeric type
couplings ， shown in figure 3-14 and 3-15. Before
replacement, carefully research the drawings, understand
the motor coupling constitutes，the drawings about motor
coupling on .table 3-3, personnel and tools on table 3-4；
For Detail should be referenced by the manual of
bubenzer.
figure 3-11：Step 11 table3-3:Drawings for motor coupling replacement

Main hoist motor coupling J607A0300
11) Clean the drum shaft and bearing pedestal with Trolley driven motor coupling J607A0400
solvent. Shaft seals should also be replaced if
Boom hoist motor coupling J607A0500
necessary.
table 3-4: Personnel and tools for motor coupling
replacement
personnel/ quantity tools/quantity
Lifting worker 1 Bottle gourd 1（10t）
welder 1 larma 1
fitter 3 Torque wrench 2
figure 3-12：Step 12
12) Install a new bearing.
3-3
Chapter THREE
figure 3-14：Motor coupling appearance
7) Take out the motor side jaw.
1 2 3 4 5 6 figure 3-17：Step 7
figure 3-15：Motor coupling sketch map
8) Take out the spider.
1 motor side coupling 2 motor side jaw
3 spider 4 reducer side jaw
5 brake disc 6 reducer side coupling

level and slacken the Boom Hoist ropes)
2) Lock out the crane’s motion for the affected drives figure 3-18：Step 8
9) Remove the motor side half coupling by larma.
3) Disconnect the coupling between the drum and the Protect the motor shaft during the process.
rotary limit switch, Use slings and softeners to
connect the drum to the service crane.
4) Tie off each of the ropes in machinery house to
remove the rope load from the drum.
5) Remove the electrical connection from the motor
brake, release the brake manually, then remove
the brake by service crane.
6) Unfasten the nuts between motor side half
coupling and motor side jaw; remove the motor
and half coupling by service crane. figure 3-19：Step 9
10) Remove the reducer side half coupling. At first,
remove the chain pulley on it.
3-4
Chapter THREE
15) Next is the procedure of re-align the new motor
11) Generally ，the chain pulley is two half forms. coupling. A bought coupling should be
Remove it by service crane. anti-corrosive treated, sealed well.
figure3-25:Appearance of folded
motor coupling
16) After unfold the cover, clean the anti-rust oil,
12) Remove the driven side jaw. heating inset the two half couplings(or by oil
bath heating)
13) Remove the brake disc. figure 3-26：Step 16
17) When re-aligning, match the serial number
between the half coupling and the brake disc.
14) Remove the driven side half coupling by larma，
Protect the reducer shaft during the process. figure 3-27：Step 17
3-5
Chapter THREE
18) Thread the heating half coupling into the, reducer

shaft for blocking proof, the quicker the better,
not overtime(ten minute).
figure 3-29：Drum coupling appearance
Thread the heating half

coupling into the,
reducer shaft for
blocking proof, the
quicker the better, not
overtime(ten minute).
1 2 3 4 5 6 1
19) Realign the motor coupling according to the figure 3-30：Drum coupling sketch map
method in chapter 2, as for coupling allowable
compensation rate, install separation, nuts torque, 1 seal 2 out cover 3 load ring
please refer to the coupling manual. 4 out dental boss 5 inner dental flange 6 inner cover
3.4 Drum coupling replacement 3.4.2 Replacement procedure
3.4.1 Preparation
The drum couplings includes main hoist mechanism, level and slacken the Boom Hoist ropes)
trolley driven mechanism, boom hoist mechanism，which 2) Lock out the crane’s motion for the affected drives
all are dental formula coupling, shown in figure 3-29 and by performing lock-out and tag-out procedure.
3-30 Before replacement, carefully research the drawings,
understand the drum coupling constitutes，the drawings 3) Disconnect the coupling between the drum and the
about drum coupling on table 3-5. personnel and tools on rotary limit switch, Use slings and softeners to
table 3-6. connect the drum to the service crane.
For Detail should be referenced by the manual of 4) Bind each of the ropes to machinery house to
Malmedie. remove the rope load from the drum.
table 3-5:Drawings for drum coupling replacement 5) Hang the drum by service crane, remove the
Main hoist drum coupling J607A0300 bearing pedestal, brake disc, and drop out the drum
Trolley driven drum coupling J607A0400 from the reducer shaft.
Boom hoist drum coupling J607A0500
table 3-6:Personnel and tools for drum coupling
replacement
Personnel/quantity Tools /quantity
Lifting worker 2 Bottle gourd 2 (10t)
painter 1 larma 1 (200t)
locksmith 3 Torque wrench 2
3-6
Chapter THREE
6) Disjoin the drum coupling step by step, and protect
the out dental boss and inner dental flange. 8) Suspended the inner dental flange by service
crane，drop out it from the drum step by step.
9) Before demounting the out dental boss, at first
estimate it if it is useful or not, If it is to be
discarded as useless, plane it from the key slot by
fire, then the coupling will drop out easily.
figure 3-33：Demounted inner dental flange
10) During the process, the reducer also can be set
down (shaft upraise vertical), it is benefit to
jacking up. Then fasten the double screw nut into
figure 3-34：Demounted out dental boss the out dental boss.
7) Then we will introduce how to demount the out
dental boss and inner dental flange separately. For
inner dental flange, at first place the drum in area
near assembly. Then unfasten the nuts on it.
3-7
Chapter THREE
14) Tighten nuts, assure the interface level up between

the raising flange and jack, completely contact.
11) Add an appropriate high mat slice，In order to
make use of the shims of the jack to rise height figure 3-42：Step 14
well，(note all the shims should be stuffed).
15) Start-up the jack. Normally, the whole procedure
need one hour, more or less.
12) Put the jack on the top of the shims steadily.
16) Next is the procedure of realign the new drum
coupling. A bought coupling should be
figure 3-40：Step 12 anti-corrosive treated, sealed well.
13) Put the raising flange at the peak, and make the
double screw through the hole in flange.
figure 3-44：Appearance of folded drum

figure 3-41：Step 13 coupling
3-8
Chapter THREE
17) For cleaning rust inhibiting oil, benefit to next step, figure 3-48：Step 20
at first, take apart the inner dental flange, outer
dental boss and abrasion indicator. 21) Telescope the out dental boss at the right place
where is on the shaft of reducer, the quicker the
better, for it will shrink in short time.
18) Clean the inner dental flange and outer dental boss
carefully.
22) After the out dental boss fixed, telescope the
abrasion indicator.
19) Heating inset the out dental boss,(or by oil bath
heating)
figure 3-47：Step 19 23) Realign the drum coupling according to the
method in chapter 2, as for coupling allowable
20) When preparation ends, start up the installation, at compensation rate, install separation, please refer
first, telescope the abrasion indicator. to the coupling manual.
24) Remark line at the abrasion indicator, according to
chapter 2.
3.5 Motor brake replacement

3.5.1 Preparation
The motor brake includes main hoist mechanism, trolley

driven mechanism and boom hoist mechanism，which are
3-9
Chapter THREE
all electric hydraulic disc brakes., shown in figure 3-51 4 brake gasket 5 brake spring subassembly 6 thruster
and 3-52, Before replacement, carefully research the
drawings, understand the motor brake constitutes，the 3.5.2 Replacement procedure
drawings about motor brake on table 3-7, the related
personnel and tools on table 3-8. 1) Lower the spreader to the ground and slacken the
For Detail should be referenced by the manual of Main Hoist ropes. ( position the boom to the level
bubenzer. and slacken the Boom Hoist ropes).
table 3-7：Drawings for motor brake replacement 2) Avoid the crane’s motions which affect save
Main hoist motor brake J607A0300 driving by performing lock-out and tag-out
Trolley driven motor brake J607A0400 procedure.
Boom hoist motor brake J607A0500 3) Only it is necessary，remove the whole brake., next
we will introduce how to replace the whole brake
table 3-8：Personnel and tools for motor brake
and its ass.
replacement
Personnel / quantity Tools /quantity
3.5.2.1 A whole brake replacement
Lifting worker 1 bottle gourd 1（5t）
welder 1 Fitter tools several 4) Remove the power wire from the thruster, remove
locksmith 2 Tension wrench 1 the L.S, and release the brake by hand.
electrician 1
5) Remove the nuts between the brake and support.
figure 3-51：Motor brake appearance
6) Suspend the brake away, mark the original
position.
1 2 3 4 5 6
figure 3-52：Motor brake sketch map
1 brake arm 2 brake draw bar 3 equalization nut figure 3-55：Step 6
3-10
Chapter THREE
7) According to the mark, full install a new brake, figure 3-59：Step 3

relocation and adjustion is needed if necessary.
4) Suspend the thruster away. Thruster internal
structure is more complicated, don not repair it in
site. If it has any fault, please remove the whole
thruster and give it to the professional person for
repairing.
5) Install a new thruster.
3.5.2.3 Spring square tube replacement
1) At first, pull out the pin roll on thruster end, bend

the thruster for laid aside firmly.
8) Remove LOTO devices and Pre-Op the crane.
Startup and monitor the crane to verify its
operation before returning it to service.
3.5.2.2 Thruster replacement
1) Take out the splint pin from up and down shaft on

thruster.
2) Turn the torque adjustable double screw bolt
counter-clockwise，release the spring force.
2) Pull out the pin roll on thruster end, bend the
thruster for laid aside firmly. figure 3-61：Step 2
3) Pull out the elastic cylindrical pin from groove
nuts,. Remove the groove nuts on square tube.
3) Pull out the pin roll on the support.
4) Pull out the splint pin from the spring support.
3-11
Chapter THREE
5) Pull out the pin roll. 2) Turn the torque adjustable screw bolt clockwise,
make sure that the screw bolt doesn’t hold back the
dummy plate under tube.
6) Put up the set square.
3) Pull out the dummy plate under spring tube by
appropriate hammer.
7) Pull out the spring square tube.
4) Turn the torque adjustable screw bolt counter
clockwise,until spring force disappear absolutely，
wrest the nuts on the bolt up end. Pull out the bolt,
spring support and spring. Install a new spring.
3.5.2.4 Spring replacement
1) Screw the torque adjustable screw bolt to nut.
3-12
Chapter THREE
3.5.2.5 Auto compensate device replacement 5) Pull out the screw shaft.
1) Remove the compensate plate.
2) Remove the splint pin on shaft, loosen the holding 6) Pull out the pin roll.
screw on the pin roll.
3) Pull out the compensate screw bolt from cross
7) Pull out the auto compensate device and set square
assembly from the brake arm.
square tube.
8) Remove the set square, take out the auto
4) Loosen the nuts on screw bolt. compensate device, install a new one.
3-13
Chapter THREE
3.5.2.6 Brake gasket replacement
1) Loosen the brake release device manually. Revolve

the adjustable nut sufficiently.
2) Pull out hand release grip.
2) Loosen the gasket binding bolt.
3) Loosen the holding bolt on idler wheel.
3) Move the gasket level for breaking away key. Then
pull out it, and re-align a new gasket.
4) Pull out the idler wheel.
3.5.2.7 Hand release device replacement
1) Loosen the holding bolt on hand grip.
3.5.2.8 Equalization nut replacement
1) Loosen the nuts under the screw bolt.
3-14
Chapter THREE
boom hoist mechanism，which are all electric hydraulic

disc brake, shown in figure 3-90 and 3-91, Before
replacement, research the drawings carefully, understand
the drum brake constitutes，the drawings about drum brake
on table 3-9, related personnel and tools on table 3-10.
This chapter of drum brake is standard piece of
ZPMC(hydraulic style)；Drum brake of ZPMC in this
project could refer to the bebenzer’s manual for SB
series Hydraulic Caliper Disc Brake.
figure 3-86：Step 1 table 3-9：Drawings for drum brake replacement
Main hoist drum brake J607A0300
2) Loosen the adjustable nut to the screw end.
Boom hoist drum brake J607A0500
table 3-10：Personnel and tools for drum brake
replacement
Personnel/quantity Tools /quantity
Lifting worker 1 Bottle gourd 1（5t）
Welder 1 Fitter tools several
locksmith 2 Tension wrench 1
electrician 1
3) Loosen the adjustable screw bolt to the screw end.
and the top nuts.
figure 3-90：Drum brake appearance
4) Pull out the screw bolt, install a new one.
figure 3-89：Step 4 1 2 3 4 5 6
figure 3-91：Drum brake sketch map
3.6 Drum brake replacement
1 brake arm 2 hydraulic cylinder 3 switch
3.6.1 Preparation 4 pedestal 5 brake gasket 6 support
The drum brake are included in main hoist mechanism,
3-15
Chapter THREE

Main Hoist ropes. (If change the drum brakes of
the boom hoist mechanism, please position the
boom to the level and slacken the Boom Hoist
ropes)
2) Lock out the crane’s motions which affect save
driving by performing lock-out and tag-out
procedure.
3) If it is necessary，remove the whole brake., next we
will introduce how to replace the whole brake and 3) Suspend the cylinder to safe place.
its ass.
3.6.2.1 Hydraulic cylinder replacement
1) Loosen the bolts on shaft end plate, remove the

shaft end plate.
4) Install a new cylinder.
2) Pull out four pin rolls between hydraulic cylinder

and brake arm one by one.
The hydraulic cylinder internal

structure is more complicated, don
not repair it in site, or it will be
very dangerous, if cylinder has
some failure, please replace the
whole cylinder to professional
person，and repair it in workshop.
3.6.2.2 Pedestal spring replacement
1) Loosen the handing bolt, remove the pedestal.
3-16
Chapter THREE

2) Loosen two screws on spring. 2) Suspend the pedestal out.
3) Move the pedestal to a safer place.
3) Pull out the old pedestal spring, and install a new
one, re-align it.
4) Loosen the holding nuts on gasket.
3.6.2.3 Brake gasket replacement
Generally, it isn’t necessary to

remove the whole drum brake,
although this way is much safer
and more effective.
1) Loosen the holding screw on pedestal pin.
5) Pull out the old gasket, install a new one.
3-17
Chapter THREE
3.7 Wheel brake replacement

3.7.1 Preparation
1 2 3 4 5 6
The wheel brakes are included in the gantry mechanism, figure 3-106: Wheel brake abridged view
which are hydraulic disc brakes, see figure 3-105 and
1 on-off key 2 fluid cylinder 3 base
3-106. Before replacement, it’s very important to read the
drawings on the wheel brake‘s structure. The drawings 4 pedestal 5 retaining piece 6 brake arm
about wheel brakes see table 3-11, Personnel and tools
placement see table 3-12. 3.7.2 Replacement procedure
This chapter of wheel brake is standard piece of Only on special conditions, the whole wheel brake
ZPMC(hydraulic style)；In this project we use the rail should be put apart. We introduce the replacement
brake which could refer to the Hillmar ’s manual . procedure of wheel brake and other unit mounts in the
following parts.
table 3-11：The drawings on rail brakes
Wheel brakes J607B0600 3.7.2.1 The whole wheel brake replacement
table 3-12：Personnel and tools 1) Lock out the crane’s motions which affect save
personnel/ quantity tools/quantity driving by performing lock-out and tag-out
Lifting worker 1 Handle gourd 1（5t） procedure.
welder 2 Fitter tools several 2) Remove the wire on the wheel brake L.S.
electrician 1 Tension spanner 1
3) Hand releases the wheel brake through the
hydraulic state.
4) Loosen the holding nuts, release the pressure in
hydraulic state, loosen the adjustable nuts, and
erase the spring force.
figure 3-105: Wheel brake natural figure
5) Remove the oil pipe on wheel brake, put the hose
to a prepared case，warding for the hydraulic oil
flowing to the ground.
3-18
Chapter THREE
6) Bracket the wheel brake by fork truck, and remove

the bolts on its support.
4) Pull out the pin roll.
7) Suspend the wheel brake by fork truck.
8) Install a new wheel brake by fork truck, connect
the oil hose, and adjust it according to chapter 2.
10) Startup and monitor the crane to verify its
operation before returning it to service.
3.7.2.2 Hydraulic cylinder replacement
5) Pull out the whole cylinder.
Hydraulic cylinder is a main
execute component on wheel
brake, need special tools to
assemble it, it is difficult to
repair it in site. If there is failure
in it, please replace the whole
cylinder to professional person
and repair it in workshop.
1) Lock out the crane’s motion which affect save

driving by performing lock-out and tag-out
procedure. figure 3-112：Step 5
2) Disappear the spring force on wheel brake, and 6) Install a new, same type hydraulic cylinder, and
remove the wire and hose imitate last step. re-assemble the L.S wire and hydraulic hose.

3) Loosen the inner hexagon screw on brake arm 7) Adjust the wheel brake according to chapter 2.
using for holding the retainer ring.
3-19
Chapter THREE
7) Screw down all the bolts.

8) Adjust the wheel brake according to chapter 2.
3.7.2.4 Pedestal spring replacement
Normally, pedestal spring will not

failure, if find some abnormal
condition, maybe the spring fall off
figure 3-114：Step 7 or others.
3.7.2.3 Brake gasket replacement 1) Loosen the holding screw.
When gasket thickness less than

2mm ， you should replace the
gasket.

2) Open the brake to the most opening span.
3) Loosen the bolts on gasket.
2) Loosen the holding pedestal, pull out the old spring,
replace a new one and mount it firmly.
4) Hold the gasket by hand, and sever it to the wheel
side, make the gasket break away the key, and pull
out it along the wheel radial.
3.7.2.5 Pedestal replacement
Normally, pedestal will not failure, if

find some abnormal condition, replace
it according following procedure.
1) Lock out the crane’s motions which affect driving

2) Loosen the spring.
figure 3-116：Step 4 3) Eliminate the fluid sealant on up and down
5) Inspect the gasket surface clean or not，deform or pedestal holding screw hole.
not , and greasy dirt or not. 4) Remove the holding pin.
6) Install a new, same type gasket along wheel radial,
and make the gasket groove aimed at join key
groove.
3-20
Chapter THREE
5) Pull out the pedestal screw.
1 bearing block 2 bearing 3 frame 4 through cover

5 driving wheel 6 driving shaft 7reducer 8 plate
table 3-13 Drawings for gantry wheels
replacement
Gantry wheels J607B0600，J607B0604，
mechanism J474B0605
table 3-14: Personnel and tools for gantry
6) Pull out the old pedestal along the wheel radial. wheels replacement
personnel/quantity Tools /quantity
Lifting worker 3 Chain block 1(5T)
welder 1 Bench tools Several
Bench worker 2 Wrench 1
electrician 1 Cylinder 250t 1
lift 1
figure 3-121：Step 6 1) Jack up the crane with no suspended load in calm

weather.
7) Install a new same type pedestal.
8) Install holding screws and wipe the fluid sealant. by performing lock-out and tag-out procedure.
9) Install the spring. 3) Move the trolley to the following position:
10) Remove LOTO devices and Pre-Op the crane.  At maximum outreach when the landside leg is
11) According to chapter2, adjust the pedestal. jacked up.
 At parking position when the waterside leg is
3.8 Gantry wheel replacement (8 wheels) jacked up.
4) The boom position is:
3.8.1 Preparation
 Raise the boom to the maintenance position
Gantry wheels are included in gantry mechanism, 8 wheels when the waterside leg is jacked up
per corner, 32 wheels in total, then 24 driving wheels,  Set the boom to the operating position when the
other 8 are driven wheel. Before replacement, it’s very landside leg is jacked up.
important to read the drawings on the gantry wheel
structure. The drawings about wheel brakes see table 3-13,
Tools and personnel shown in table 3-14.
3-21
Chapter THREE
At the jack point, use a

Jacking-Up support connected
with small equalizer beam by bolts
where the replacement is located
at and a 250t hydraulic jack with
at least 500mm strokes on this
support. The center line of jack
should match the center line of
rail. The wheel load value listed in
chapter1.The jack capacity to jack
up the lower equalizer beam is at
least four times of the wheel load). figure 3-112：Step 7
5) Align the hydraulic jack to center of lower 8) Fall the bogie on the rail slowly, then translate it
equalizer beam. The jacking-up support contact laterally, move the bogie to the workshop by fork
with lower equalizer beam by bolts. Jack up the truck.
lower equalizer beam and have a forklift to hold
the truck whose broken wheel is to be replaced. So
there will be no load at truck pin.
9) Remove the cover and pins of anti-torque plate
out and loose and bolts of up-tight plate finally.
6) Jack up the equalizing beam by another jack, this
procedure should match with big jack at the jack
point, until the clearance between shaft and hole is
equal.
10) Remove the reducer.
7) Push the shaft by hand.
11) Remove the end-plate of wheel in the workshop
3-22
Chapter THREE
first, install additional pipe for larma on screw hole

in bearing block.
figure 3-116： step 11

12) Remove the bolts on bearing block.
15) Install the carrier rod of larma.
16) Install the hydraulic jack. Match the face between
shaft end and jack. Then start up.
Figure 3-118：Driving shaft apparent after step

12
13) Suspend away the wheel from the bogie by
service crane. figure 3-122：Step 16
17) Pull out the bearing.
14) Pull out the shaft from the bearing by larma. At
3-23
Chapter THREE
18) Pull out the bearing by hand. end-plate and bolts.

22) Adjust the bolts according to the requirements
for up-tight plate of reducer, install the cover for
up-tight plate.
23) Assemble onto the equalizer beam, and then
finish the whole replacing process.
The procedures for driving wheel are same with
driven wheel, except the details for reducer and
up-tight plate.
19) Pull out the bearing pedestal. 3.9 Trolley wheel replacement (4 wheels-rope towing)
3.9.1 Preparation
Trolley wheels are included in the trolley ass, 1 wheels

per corner, 4 wheels in total. For the pull type trolley, all
the wheels are driven wheels. The wheels structure is
shown in figure 3-126. Before replacement, it’s very
important to read the drawings on the trolley wheel‘s
structure. See table 3-15&3-16
table 3-15:Drawings for trolley wheels
replacement
Trolley wheel ass. J607A0200&J474B0202
20) Re-assemble the bearing and gantry wheel in
contrary above on the gantry mechanism and
equalizing beam.
21) Install the hollow shaft of reducer, install the
figure 3-126：Trolley ass view
1 wheel 2 bearing 3 eccentric bearing 4 frame

5 shaft 6 pedestal
3-24
Chapter THREE
table 3-16: Personnel and tools for trolley wheels replacement

Personnel and tools placement are shown as below:
personnel/ quantity Tools/quantity
Lifting worker 3 Handle gourd 1（5t）
welder 1 Fitter tools several
Locksmith 2 Torque spanner 1
Llectrician 1
On running, if there is noise or

splashing metal dust from the
wheels, you should stop at once and
check it, make an adjustable scheme.
The checking of New QC during

running-in time（150～300h）, is very
important. When built-in stress is
released, trolley frame will deform
appreciably, then check the trolley
wheel and adjust it.
1 2
On the end of adjusting, trail run
with empty load, if well , then trail figure 3-128：Assay plan for wheel eccentric adjust
run with rated load.(20～30t, During
this period, if there is anything 1 trolley wheel 2 eccentric sleeve also bearing block
wrong, adjust the wheel eccentric
sleeve seat 2~5degree until 3.9.3 Eccentric sleeve assemble
acceptable.
1）The prepared eccentric sleeve.
Trolley wheels replacement need many
technologies,，please read ZPMC method carefully. 2）Install the bearing on the wheel.
Each trolley wheel is supported by two anti-friction
bearings which are housed inside two eccentric bearing
3）Install the seal on the end cover.
sleeves, Both eccentric bearing sleeves are 1.5mm 4）Install the end cover on the wheel.
eccentricity.
5）Install the wheel on the shaft.
6）Install the bearing seat on the wheel shaft.
7）Install the whole wheel shaft on the support,
adjust the sleeve and then tighten the bolts to fix the
it. After adjusting the position of the wheel shaft,
tighten the bolts on the cover.
3.9.4 Trolley wheel replacement
1）Move the trolley to the backreach (at its wheel

Mark for measuring the position
maintenance position) and make sure the jack up point
figure 3-127：Mark on trolley wheels on the trolley frame.
2）Lower the spreader to the ground and slacken the
main hoist ropes.
3）Perform the emergency stop to forbid all the
process that influence the safety.
4）Install a 10T jack under jacking pads which are on
the transverse centerline of the trolley (parallel to the
3-25
Chapter THREE
gantry rail). The gap between the top of the rail and the 3.9.5 Wheel adjustment analysis
bottom of jack point is about 300mm. Rise the truck
10 mm. A timber block may be necessary between the Through different turning combinations of these two
trolley frame and rail top to prevent the trolley from eccentric sleeves, the trolley wheels can be re-aligned in
tilting. The anti-lift plate may be removed from the three conditions. 1) Horizontally Deviated; 2) Vertically
trolley before jacking-up. leaned; 3) Vertical Lift-off.
1) Trolley Wheel in original position
5）Loosen the bolts between the cover and sleeve

thereby disconnecting the truck with defective wheel 2 1 2
or shaft. Lift the truck up with the back reach overhead figure 3-129：Trolley wheel in original position
bridge crane, transfer to the electric jib hoist at the
back reach and lower it to the ground. 1 wheel 2 Original Pos. Mark on eccentric sleeve
Figure 3-129 shows the trolley wheel in its

It is recommended that trolley wheel original position. The eccentricity of the bearing sleeve
or axle repair work be accomplished is exaggerated (not in scale, for a more clear view)
in a workshop instead of on the IMPORTANT! Please locate the original position
crane. mark. If the mark is not there, make sure that you mark
it before starting any disassembly. This will give you a
6） Disassemble the truck at the workshop. When definite direction of sleeve turning. You can return to
disassembling the truck, first remove the wheel bearing the original position if the adjustment fails (gets worse
end covers, and then make marks on the outside after the adjustment).
surface of bearing seats (eccentric sleeve) and truck. 2) Wheel Horizontally Deviate
The wheel bearing’s seat is Figure 3-130 shows how to make the wheel
eccentric. The purpose of this design deviated horizontally. Turn the left sleeve 90 degree
is that the axial alignment of trolley clockwise, and turn the right sleeve 90-degree counter
wheels on both sides of rails can be clockwise. The wheel can be deviated horizontally to
adjusted to proper value. the left up to 0.97 degree. At the same time, the wheel
will be elevated off the rail by 2.5 mm. If you turn the
7）Pull out the bearing. two sleeves in the opposite direction, the wheel will be
deviated to the other direction.
8）Pull out the bearing.
9）Remove the old bearing.
10）Install the prepared bearing and bearing seat on the
trolley wheel.
11）Suspend the new wheel into the shaft to assemble.
12）Install the sleeve on the shaft and then install the
end cover and through cover.
13）Lift the new wheel and shaft by service crane at
back reach, and translate them to the ground,
re-assemble the pin roll. 1 2 3
figure 3-130：Wheel Alignment (Horizontal)
14）Install the check plate and positioning bolts.
1 wheel elevate 2.5mm 2 rotate 90 degree clockwise
15）Install the bumper and other components, trail run
3 rotate 90 degree counter-clockwise
the trolley.
3) Wheel Vertically Leaned
3-26
Chapter THREE
When doing this adjustment, please

gradually turn the eccentric sleeve.
Every time, a 15~30 degree angle
turning is recommended, then see if
the trolley running condition has
been improved. If necessary, turn
another 15~30 degree.
1 2 3
Figure 3-132：Wheel Lift-off
1 rotate 180 degree 2 rotate 180 degree

3 wheel elevated 2.5mm
Figure 3-132 shows how to make the wheel

vertically lift-off. Turn both the left and right sleeve
180 degree (either clockwise or counter clockwise).
1 2 3 The wheel will be lifted vertically off the rail by 5 mm.
figure 3-131：Wheel Alignment (Vertical) If you do this by turning both sleeves 90 degree in the
same direction, the wheel will be lifted off by 2.5 mm
1 wheel elevate 2.5mm 2 rotate 180 degree clockwise and there will be no wheel deviation and wheel
3 not rotate leaning。The relationship between wheel alignment and
eccentric sleeve turning is shown in table 3-17.
Figure 3-131 shows how to make the wheel
leaned vertically. Turn the left sleeve 180-degree table 3-17 : Wheel Alignment vs Eccentric
(either clockwise or counter clockwise), and the right Sleeve Turning Combination
sleeve stays un-turned. The wheel can be leaned Combination 1 Combination
vertically to the right up to 0.97 degree. At the same 2
time, the center of the wheel will be raised the rail by Right Sleeve 90º Do not
2.5 mm. If you do the two sleeves in the opposite rotate
direction, the wheel will be leaned to the other
direction.
Left Sleeve 90º 180º
Wheel Alignment Results
Horizontally √
If turning one eccentric sleeve Deviated
at 30, 60or 90 degrees, the Vertically √
wheel will both leaned leaned
vertically and deviated Vertically √ √
horizontally. When one lift-off
eccentric sleeve is turned 90 Combination 3 Combination
degree, half of the maximum 4
deviation angle of 0.97 degree Right Sleeve 180º Do not
and half of the maximum rotate
leaning angle of 0.97 will be
distributed evenly. You can do
Left Sleeve 180º 90º
this if the wheel needs both
deviation and leaning Wheel Alignment Results
adjustment. Make sure the Horizontally √
deviation and leaning direction Deviated
is correct before doing this! Vertically √
(This decides which sleeve will leaned
be turned and what the turning Vertically √ √
direction is.) lift-off
4) Wheel Vertical Lift-off
3-27
Chapter THREE
try this way to settle it:

The horizontal angular
deviation of wheel axis to its  If the wheel horizontal deflection angle is not big,
theoretical position should be near the permission offset, and wheels are rotated
less than 0.04%. inside, then rotate the opposite wheels with same
angle inside.
 If the wheel horizontal deflection angle is too
big，or wheels are rotated outside，then according
to the second method to adjust wheels.
Sometimes , two deflection

wheels inside are better than
two parallel wheels , just like a
car, his two front wheels are
deflectable inside to keep
running straightforward,. And
applicant the method in QC
need more practice experience.
The misalignment of the two 2) Illustrate for Wheel Vertically Leaned
opposite wheels’ on two opposite
rails. If the wheels are mounted
on opposite bogie then the
misalignment of opposite pins in
the vertical plane should be less
the 0.15% of the span, or a
maximum of 2mm.
figure 3-134：Wheel Vertically Leaned

The figure above shows that wheel deflect
3.9.6 ILLUSTRATE FOR TROLLEY WHEELS vertically. Wheels will contact with inside rail.
ADJUSTMENT Normally it means rail side abrasion not asymmetry,
and the other side rail will rusted, the wheels is the
1) Illustrate for Wheel Horizontally Deviate same condition, if the interface is caught down, the
contact stress will increase, and the same to noise and
vibration，then according to the third method in 3.9.5
to adjust wheels，but do not change the wheels in
horizontal angle at same time.
3）Adjustment procedure:
a) Remove the bolts on bearing block cover board.
b) Loosen the half seat to rotate the eccentric sleeve.
c) Find the peak on eccentric sleeve (three points).
figure 3-133：Wheel horizontally deviate d) Lift the wheel until above rail 2-5mm.
The figure above shows seaside left wheel e) Measure the horizontal deviate.
deflects horizontally. When trolley is running from
landside to seaside, seaside horizontal wheels will f) Fasten the bolts on eccentric sleeve, if necessary,
extrude the left rail. Scream, or splash metal rust, then rotate the eccentric sleeve to right angle by pontil
3-28
Chapter THREE
or other tools.
g) Put the trolley down, resume it to the normal
condition and trail run for check and adjustment
effect.
3.10 Main hoist pulley replacement

3.10.1 Preparation
The main hoist pulleys are included trolley frame,

headblock、girder end, 18 in total. The nylon pulley at
boom end which only for rope re-reeving needn’t
replaced, so the pulleys following are the forged one at 1 2 3 4
other positions, 16 in total. The main hoist pulley pulleys figure 3-136：Main hoist pulley sketch map
constitutions are shown in figure 3-135& 3-136, before
replacement, carefully research the drawings, understand 1 end cover 2 seals 3 bearing 4 pulley
the pulley constitutes，the drawings about pulley on table
3-18, personnel and tools on table 3-19.
1) Move the trolley to backreach so that the sheaves
table 3-18：Drawings for pulley replacement which are to be replaced are accessible with the
outside service crane at backreach.
J607A0200，
Main hoist pulley at TRSA07a-J474A， 2) Lower the headblock to the ground and slacken
trolley TRSA08a-J474A the main hoist ropes.
ZMHL900-Eb 3) Lock out crane hoist and trolley motions by
Main hoist pulley at J607B1200， performing the lock-out and tag-out procedure.
headblock ZMHL900-Eb
4) Loosen the 4 bolts and pin connected the shaft
Pulley in Anti-Snag J474A1000， upper seats with the structure of trolley frame.
device ZMHL900-Eb
table 3-19：Personnel and tools for pulley pin bolt
replacement
personnel/quantity tools/quantity
Lifting worker 1 Bottle gourd 2（0.5t）
Locksmith 2 Fitter tools several
Electrician 1 Tension wrench 1
5) Use two 0.5t chain hoists to remove the ropes
from the sheaves which are to be replaced.
6) Remove the 2 shaft upper-seats and lift up the
sheave assembly. Once the ropes are clear of the
sheaves, place a timber across the opening where
figure 3-135：Main hoist pulley appearance the sheaves were and released the rope wire onto
the timber. Pull the bridge toward landside to let
the sheave assembly be accessed by the electrical
hoist on the jib.
7) Lower the sheave assembly to the ground and
repair damaged sheave assembly parts in a
workshop.
3-29
Chapter THREE

8) Tap out the shaft, don’t damage the lubrication
hole.
figure 3-142：Dummy plate between pulleys

11) After unfastening the pulley, remove the bolts on
figure 3-139：Step 8 trouble pulley end cover.
9) Suspend the shaft away by service crane in
workshop.
12) Pull out up half bearing by larma.
10) Separate the two pulleys by service crane. figure 3-144：Step 12
3-30
Chapter THREE
figure 3-145：Dummy plate between bearings

13) Pull out the dummy plates.
figure 3-147：outer dummy plate（brown part）

14) Turn over the pulley, pull out another bearing by
the same way.
15) Re-assemble the pulley by reverse procedure.
3-31
上 Shanghai Zhenhua Quayside Container Crane
Heavy Industries Co.,Ltd. Chapter FOUR
Chapter 4 wire rope
(c) Independent Wire Strand (d) Independent Wire Rope

This chapter will introduce the common
Cores(IWSC) Cores(IWRC)
knowledge of the wire rope. If the
conflict exists, the instructions provided Figure 4-2：Core of wire rope
by the wire rope supplier shall be
4.1.3 Type of laying
preferential. There may be different
regulations for the usage, maintenance, 1) Direction of Laying
discarding of the wire rope that shall be
As concerns the direction of laying the rope and
strictly followed in different countries.
the strand, there is the Z lay and the S lay, as shown in
Figure 4-3. in the case otherwise specified, the rope
4.1 Basic knowledge of wire rope
shall be made of Z lay and the stand products of the S
4.1.1 Construction lay.
2) Laying of rope
There are two types of lay as shown in table 4-1:
 Ordinary lay(or regular lay)：The lay of the

rope and the lay of the strands are in opposite
directions.
 Lang’s lay：The lay of rope and the lay of the
strands are in the same directions.
Figure 4-1：Wire rope appearance (example) Table 4-1：Laying of wire rope
laying of rope advantage disadvantage
4.1.2 Core
Long silk
The core of the wire rope used for quayside on the
container crane are shown in figure 4-2(d). surface,
wear-resisti
Big torque
ng, soft and
anti-fatigue,
bend
resistance
(a) Fiber core (b)Wire and Strands fiber core

Hard and
esay to Bad bend
operate, resistance
fixed tightly
1
3) The length of a laying
Generally, The length of a laying (length of rope

pitch) is usually 6.2~8.2 times of the wire rope
diameter. The measurement of the length of a laying is
Figure 4-3：Measurement of a laying
shown in Figure4-3（For a wire with 6 Srtands）：
4.2 Handling of wire rope
4.2.1 Transportation and storage
To prolong their life, the wire rope must be

properly transported, stored, cleaned, inspected and
installed. Wire ropes are easily affected by external
damage. Therefore, they must be handled with utmost
care during transport and unloading. All wire ropes
should be stored clean, dry and cool and soil contact
must be avoided anyway. Wire ropes must always be
handled with equipment that will not damage the rope.
(a)
Reels of wire rope should be stored in an area
where they will not be damaged by objects falling,
chemical spills, excessive heat, open flames, welding,
and excessive heat. Reels should be stored vertically
on their flanges and covered to prevent dirt and debris
from embedding into the wire. When storing reels,
ensure that one reel will not roll into another. This will
prevent one reel flange from hitting the wire rope
surface of another reel. If necessary, reel flanges
should be choked to prevent movement. The wrong
method as shown in Figure4-4 shall be prohibited. For (b)
the correct method handing the rope, please refer to
错误！未找到引用源。5.
Do no t st o re w i re ro pe in
a t mo sp he re o f v o la t il e che mi ca l
o r mo i st u re. Wi re ro p e w ill r u st .
Do no t u se a ny de t erg e nt o i l t o
clea n w i re ro pe. Det erg ent o il Prevent
so a ks i nt o a nd d is so lv e s t he rolling down!
lu br ica nt i n si de t he ro pe a nd w i ll (c)
ca u se in t er na l co r ro sio n. Clea n Figure 4-4：Un-recommend method
w it h a w i re br u s h.
2
(a) (a)
(b) (b)
Figure 4-5：Recommend method
4.2.2 Installation of wire rope
Proper/improper methods of unwinding a wire

rope from a reel are separately introduced in Figure
4-6, Figure 4-7.. Considerable care must be taken
when unwinding a wire rope. Their operational
performance is substantially influenced by the way
they are handled. Bending or twisting wire rope can
cause internal damage that will adversely affect the
operational life of the wire rope. Avoid unwinding wire (c)
rope on the ground to protect the wire rope from debris.
If there is no other option, make sure the ground is
clean or covered with boards or plastic sheets.
Every wire rope bends in a particular direction

based on the lay of the rope. So, the wire rope should
always be uncoiled that coincides with their lay. As
shown in Figure 4-8 the prohibited methods of
unwinding a wire rope, wire rope should never be
pulled out with the reel fixed. (d)
Figure 4-6：Improper method
3
(a) (e)
(b)
(f)
Figure 4-7：Proper method
If w i re ro pe i s u n re ele d w it h t he
ree l f i xe d, w i re ro pe w i ll be
t a ng l ed a n d w il l ca u se ki n k o r
def o r ma t io n .
(c) 4.3 Termination and treatment of wire rope end
4.3.1 The wire rope clip
4.3.1.1 clips
(d)
4
Figure 4-8：Distance between clips
Rope end connections using wire rope clips are

very popular because they can be fabricated on-site
with very little effort and they are also very cheap. Figure 4-9：End connections with rope clips fitted
Compared with many other end connections they are incorrectly
easily detachable and can be inspected without
difficulties. The rope end is always laid around a 4.3.1.2 The asymmetrical wedge socket
thimble and the first clip is threaded on close to the
When terminating a rope end with a wedge socket,
thimble.
ensure that the rope tail can not withdraw through the
The distance between clips is approximately socket by securing a clamp to the tail or by following
equal to the width of the clip as shown in Table 4-2. the manufacturer’s instructions. The tail length should
The minimal quantity of clips used for an end and the be a minimum of 20 rope diameters for all Rotation
minimal tighten torque shall follow the values as Resistant wire rope and a minimum of 6 rope
shown in Table 4-2.. The incorrect installation of clips diameters for 6 and 8 strand ropes
such as shown in Figure 4-9 may reduce its breaking
See Figure 4-10 for two recommended methods of
load considerably and results in unexpected accident.
securing the rope tail of a wedge socket termination.
Table 4-2：Tightening torques for rope clips
The installation as shown in Figure 4-11 shall be
prohibited in any case.
Nominal size Torque [Nm] clips number
5 2.0 3
6.5 3.5 3
8 6.0 4
10 9.0 4
13 33 4
16 49 4
19 67.7 4
22 107 5
26 147 5 Figure 4-10：Recommended clipping of the ‘dead’
30 212 6 line
34 296 6
40 363 6
5
Figure 4-11：Incorrect installation of a wedge

socket connection
4.3.1.3 Other methods of rope end connection
There are also many other methods for the rope end
connection as shown in Figure 4-12 such as:（a）The
splice，the oldest end connection for ropes, is not used
very often and may only limited to some wire ropes in
very small size and used for secondary application in the
container cranes. (b) The aluminum clamp that usually (c)
shall be fabricated by the specially machine.(c) swaged Figure 4-12：Other rope end connections
sockets and etc.
4.3.2 Wire rope cutting and treatment of rope end
In every case, each side of the cut must be

properly seized to prevent strand disturbance before
cutting. After all the seizing are secure, then you may
cut the rope. Normally, one seizing on each side of the
cut is sufficient. For non-preformed or rotation-
resistant ropes, a minimum of two seizing on each side
is recommended. These should be spaced six rope
diameters apart. The procedures of cutting are below:
(a)
1) The rope and this wire end are now wrapped
moving away from the location of the intended
cut. Keeping wraps parallel, close together and
in tension. Twist ends of strand together by
hand.
(b)
2) The rope is tightly wrapped for a distance of
approx two three rope diameters.
3) Both ends of the seizing wire are then pulled

tight and twisted together. The twisted
connection is then hammered into a strand
valley.
4) After preparing the other side of the intended

cut accordingly the rope can now be cut. Please
also see Figure 4-13 for details.
6
Step 1)
(c) Seized and torch cut with ends fused
Step 2)
(d) Steel end link
Step 3) Figure 4-14：Treatment of rope end
4.4 Inspection of wire rope
A steel wire rope is a commodity with a limited

lifespan. There are many factors that may influence the
rope life and performance such as: the quality of the
Step 4)
rope, load during the operating, operational
environment, maintenance etc. Many properties will
change and many damages may have during its service
especially before the failure of the rope. Those changes
Figure 4-13：Wire rope cutting and damage may be the premonition of the failure of a
Most ropes are shipped with the ends seized as wire rope. So regular inspection is very necessary to
they are prepared for cutting as shown in Figure eliminate any hidden defect to extent the rope life or
4-14(a). You can usually install seized ropes without find premonition of rope failure before rope changing.
further preparation. In some cases, though tight The factors influence the rope life, the properties
openings in drums and wedge sockets- or even changes and the damages are also recorded during the
complicated reeving systems – require special end inspection so the reasons of rope failure can be
preparation. Then, the strands must be tightly held analyzed and the deterring factor can be reduced to the
without increasing the rope diameter. In such cases, the minimal.
ends are tapered and welded as shown in Figure 4-15
T he p ro p ert ie s o f w i re ro pe w il l
(b) (c), or the ends fused as shown in Figure 4-15(d).
ra p id ly dec rea se b ef o re rea ch ing
It’s sometimes necessary to provide a loop or link to
t he ro pe lif e t i me . S o t he
which a lighter line is fastened to pull the rope into
in s pect io n i nt e rv a l s ne ed t o be
place or around sheaves. Some of these special end
sho rt e ne d bef o re ro pe
preparations are shown as follows:
re pla ce me nt f o r t he sa f et y.
4.4.1 The factors influence the rope life
(a) Seized end There are many factors that may influence the
rope life and performance including the condition of
operating, maintenance, working environment etc.
and is very complicate. To a rope on shore container
crane, some main factors: are below:
(b) Tapered and welded end
7
1) he ropes are subjected to the changing load 3) Small diameter sheaves can result in
when running through drums and sheaves permanent set of the rope, and will certainly
continuously so the ropes are bended lead to early wire breaks.
constantly during all the operation and is
4) Oversize grooves offer insufficient support to
easily fatigue.
the rope leading to increased localized pressure,
2) The corrosion due to the humidity and salt flattening of the rope and premature wire
spray in a marine environment: The air is fractures. Grooves are deemed to be oversize
mixed with humidity and salt which is when the groove diameter exceeds the nominal
liquefiable in water. The ions in water will rope diameter by more than 15%.
speed up the diffusion of oxygen ion and that
5) Undersize grooves in sheaves will crush and
also speed up the oxidation reaction of wire
deform the rope, often leading to two clear
rope and worse the corrosion of it.
patterns of wear and associated wore breaks.
3) Affect of foreign objects embed in the wire
rope. The wire ropes are working on an
6) Excessive fleet angle can result in severe wear
of the rope due to scrubbing against adjacent
opening adverse polluted environment. The
laps on the drum. Rope deterioration at the
wind are also very stronger that may bring the
termination may be exhibited in the form of
hard foreign objects such as graves, slag and
broken wires. An excessive angle of fleet can
etc to the surface of the wire rope and then go
also induce rotation causing torsion imbalance.
to the sheaves, drums, or even inside of the
wire ropes that may cause wear and wire 7) Using the wire rope of incorrect size,
broken. construction, or grad.
4) Affect of frequency operating: There is only a 8) Dragging rope over obstacles.

thin film of lubricant on the surface of the wire
rope. The lubricant is squeezed out from 9) Having improper lubrication.
internal of rope when the rope is tensioned and
10) Operating over sheaves and drums with
drawn in when the rope is loosed. This is improperly fitted grooves or broken flanges.
frequency duplicated and not only causes the
escape of the lubricant inside the rope but also 11) Jumping off sheave.
speeds up the oxidation of the lubricant.
12) Subjecting it to acid fumes.
Of course, there are many factors that may affect the
13) Attaching fittings or installation improperly.
life of the wire rope. Those factors may not only related
to the design but also including a lot of abnormal factors 14) Subjecting it to severe or continuing overload.
such as:
4.4.2 Inspection Method
1) Multi-layers of the rope on the drum can
The measurements shall be taken by the
result in severe distortion in the underlying
qualified people.
layers.
1) Measurement of diameter
2) Bad spooling (due to excessive fleet angles or
slack winding) can results in mechanical The size of a wire rope is designated by its
damage, shown as severe crushing, and may diameter. The diameter of a wire rope should be
cause shock loading during operation. measured by a set of Venire calipers.
8
The correct measurement of the rope diameter is

shown in Figure 4-16(a). The measurements as shown
in Figure 4-16(b) are wrong.
T he no mi na l d ia me t e r o f a new
 w ire ro pe mu s t b e mea s u re d a n d
reco rd ed b ef o re it i s in st a l le d o n
t he cra ne. Th e re su lt s o f ev ery
su b se q ue nt c he c k s ho ul d a l so be Figure 4-16：Detecting wire breaks by bending
reco rd ed i n t he j o ur na l f o r t ha t the rope
w ire ro pe.
(a) Correct measurement of the rope diameter
(a) (b)
Figure 4-17：Examine the interior of the wire rope
3) Tactile inspection
The Tactile inspection is often used to detect the

wire breaks by spooling the rope through your hand
(b) Wrong measurement of the rope diameter (only if the rope can be run slowly enough). This
Figure 4-15：Wire rope measurements method is usually to be used together with the visual
inspection simultaneously. When applying this method
2) Visual inspection extreme care is necessary as protruding wires from the
rope construction can cause severe injuries. In many
Visual inspection is the method most wildly used.
cases the inspector will run a piece of wood along the
The wire rope surface shall be cleaned before inspection.
rope which is ten kicked back by the protruding wire
Wire breaks of outer wire which do not occur at the
break ends. Another useful technique is to hold a ring
crowns of the strands but at the contact points of two
of cotton waste around the slow moving rope-any
neighboring wires or even on the underside of the strands
protruding broken wires will snag the cotton and
are very difficult to detect. With thin ropes, which can be
thereby highlight the damaged area.
completely unloaded, such wire breaks can be made
visible by extreme bending of the rope as shown in 4) Magnetic testing of wire ropes (NDT)
Figure 4-16. The interior of wire rope can be examined
according toFigure 4-17. There are some wire rope NDT machines to
detect both surface and interior damages in the
marketing. The advantages of this instruments are they
good at detect the damages not visible or interior the
wire rope and even can inform the inspector about the
9
extent of the rope deterioration. But the reliability of such as snag or in the case of presumed no-visible
this kind of new techniques needs to be verified by the damage or installation of a new rope, the wire rope
practice. For the details please reference the manuals shall be inspected immediately. The intervals shall also
of this kind of machine. be reduced after that.
ND T u s ing el ect ro ma g n et ic The intervals shall also be shorted whenever any

me a n s ma y b e u s ed t o det e ct damage has occurred in connections with the reeving
b ro ken w i res a n d lo s s i n met a lli c system especially before the period of the rope to be
a rea . T hi s met ho d co mple me nt s discarded.
t he v i sua l e xa mi na t io n but do es
T he int erv a ls o f i n sp ec t io n ca n
no t re pla ce it .
be a dj ust ed a cco rd i ng t o t he
4.4.3 Where and when must wire ropes be p rev io u s i n s pect io n rec o rd.
inspected?
4.4.4 What shall be inspected?
Generally speaking the whole wire rope length
A thorough inspection should cover the following
must be visually inspected. It goes without saying that
points:
critical zones require extra attention. For example,
critical zones are: Those rope zones which are exposed To detect the abrasion and breaks early and on
to the highest number of cycles, rope end connections, time, a schedule shall be set for each rope. A thorough
loading points; rope zones on compensation sheaves; inspection should cover the following points:
rope zone on rope drums and etc. The rope zones on
compensation sheaves are easily to be ignored because 1) Determining the rope diameter: Measure the
it is usually wrongly though “this zone are static and diameter of wire rope and check the reduction
compensation sheaves do not work (as everybody in rope diameter and the rate of the reduction.
known’s) permit a smaller diameter for this very 2) Is there the rope corrosion? Is the rope
sheave.”. So, the piece of rope in this zone not only properly lubricated?
carries out more bending cycles (especially due to the
jumping) than the others but also is on a sheave with a 3) Abrasion includes outer and interior of the
smaller diameter. Special care shall also be taken to the rope.
rope zones in the grooves of sheave and drums nearby 4) Are there any visible break wires? What kind
rope out points. of break wire it is? The rope shall be discarded
if the break wire reaches a specified numbers.
As far as possible, all visible parts of any rope
shall be observed each working day with the objective 5) If there is a phenomenon that the wire rope has
of detecting general deterioration and deformation. been crushed, abraded, flattened, Basket or
Particular attention shall be paid to the rope at points lantern deformed kinked or has sustained any
of attachment to the crane. other damage that distorts it; the rope should
be discard.
The wire rope shall be inspected one week after
fisting using or the wire breaks firstly be found. 6) Inspection the rope connections and parts
connected with the wire: What’s condition of
After first inspection, inspect the wire rope
the connection? Damaged connection shall be
monthly.
changed or corrected immediately. Is the
After abnormal loading or whenever an accident abrasion of the drum and sheave grooves reach
10
allowable tolerance? However, deterioration frequently results from a

combination of factors, giving a cumulative effect
All inspection results shall be well recorded in the
which should be recognized by the competent person,
daily log and special record for wire ropes.
and which reflects the decision to discard the rope or
to allow it to remain in service. Particular attention
T he re s ult s o f ev ery v i s ua l
shall be paid to the abnormities that may damage the
in s pect io n s ha ll be rec o rde d f o r
rope and shall be eliminated before rope changing.
t ra c ki ng p ur po se s.
The discard criteria can be found in ISO
A Typical example of rope examination record is
4309:2004（E），DIN15020, DIN3088 and etc. The
given in ISO 4309:2004(E) Annex B that could be
local criteria shall be taken priority of those criteria.
referenced. The wire rope discard date ad discard
number of cycles could be predicted the series of wire The content of discard criteria of ISO 4309:2004
rope inspection record. The records of inspection are （E） is as below:
also important material for analyzing the key factors
affecting the rope life so the measures to improve the 4.4.5.1 Nature and number of broken wires
rope life can be found.
In the case of 6- and 8-strand ropes, broken wires
4.4.5 Discard criteria usually occur at the external surface. In the case of
rotation-resistant ropes, there is a probability that the
The safe use of wire rope is qualified by the
majority of broken wires will occur internally and are
following criteria:
“non-visible” fractures. Detail criteria are given in
1) Broken wires: the nature and number of Table 4-3.
broken wires; broken wires at the
4.4.5.2 Broken wires at termination
termination; localized grouping of wire
breaks; the rate of increase of wire breaks. If there are broken wires at, or adjacent to the
2) The fracture of strands. termination, the cause of this deterioration shall be
investigated and, where possible, the termination shall
3) Reduction of rope diameter, including that be remade, shortening the rope if sufficient length
resulting from core deterioration. remains for further use, otherwise the rope shall be
discarded.
4) Decreased elasticity.
5) External and internal wear. 4.4.5.3 Localized grouping of broken wires
6) Deformation: waviness; Basket or lantern Where broken wires are very close together,
deformation, core or strand protrusion constituting a localized grouping of such breaks, the
/distortion, Wire protrusion; local increase in rope shall be discarded. If the grouping of such breaks
diameter of rope, flattened portions, Kinks or occurs in a length less than 6d or is concentrated in
tightened loops; bends. any one strand, it may be necessary to discard the rope
even if the number of wire breaks is smaller than the
7) Damage due to heat or electric arcing.
maximum number shown in Table 4-3. Pictures 3 in
8) Rate of increase of permanent elongation. Table 4-4 show the typical localized grouping of
broken wires. They are usually the main damages to
All examinations shall take into account these the main hoist and trolley towing ropes.
individual factors, recognizing the particular criteria.
11
4.4.5.4 Rate of increase of broken wires Decreased elasticity is difficult to detect.

However, it is usually associated with the following:
In applications where the predominant cause of
rope deterioration is fatigue, broken wires will appear 1) reduction in rope diameter.
after a certain period of use, and the number of breaks
2) Elongation of the rope lay length.
will progressively increase over time. In these cases, it
is recommended that careful periodic examination and 3) Lack of clearance between individual wires
recording of the number of broken wires be undertaken, and between strands, caused by the
with a view to establishing the rate of increase in the compression of the component parts against
number of breaks. This premise may be used to each other appearance of fine, brown powder
propose a future date for rope discard. between or within the strands.
4.4.5.5 Fracture of strands 4) Increased stiffness.
If any above phenomenon are observed or

If a complete strand fracture occurs, the rope shall
examiner has any doubt, advice shall be obtained from
be immediately discarded.
a specialist. Increased stiffness of a rope can lead to
4.4.5.6 Reduction of rope diameter resulting abrupt failure under dynamic loading and is sufficient
from core deterioration justification for immediate discard.
Reduction of rope diameter resulting from 4.4.5.8 External wear

deterioration of the core can be caused by:
See picture 13 in Table 4-4 for the reference.
1) Internal wear and wire indentation. Wear is promoted by lack of lubrication, or incorrect
lubrication, and also by the presence of dust and grit.
2) Internal wear caused by friction between
Wear reduces the strength of ropes by reducing the
individual strands and wires in the rope,
cross-sectional area of the steel strands. If, due to
particularly when it is subject to bending.
external wear, the actual rope diameter has decreased
3) Deterioration of a fiber core. by 7 % or more of the nominal rope diameter, the rope
shall be discarded even if no wire breaks are visible.
4) Fracture of a steel core.
4.4.5.9 External and internal corrosion
5) Fracture of internal layers in an
otation-resistant rope. Corrosion occurs particularly in marine and
polluted industrial atmospheres. It will diminish the
If these factors cause the actual rope diameter to
breaking strength of the rope by reducing the metallic
decrease by 3 % of the nominal rope diameter for
cross-sectional area, and it will accelerate fatigue by
rotation resistant ropes, or by 10 % for other ropes, the
causing surface irregularities which lead to stress
rope shall be discarded even if no broken wires are
cracking. Severe corrosion can cause decreased
visible.
elasticity of the rope.
4.4.5.7 Decreased elasticity
Corrosion of the outer wires can often be detected
Under certain circumstances elasticity decreasing visually. See picture 14 in Table 4-4.
is usually associated with the working environment, a See Picture 14 in Table 4-4 for the internal
rope can sustain a substantial decrease in elasticity and corrosion. It is more difficult to detect than the
is thus unsafe for further use.
12
external corrosion which frequently accompanies it, rope shall be discarded if the basket or lantern
but the following indications can be recognized: deformation occurs.
1) Variation in rope diameter; in locations 4.4.5.12 Core or strand protrusion/distortion

where the rope bends around sheaves, a
reduction in diameter usually occurs. See picture 5, 7 in Table 4-4. Rope with core or
However, in stationary ropes it is not strand protrusion/distortion shall be immediately
uncommon for an increase in diameter to discarded.
occur due to the build-up of rust under the
outer layer of strands. 4.4.5.13 Wire protrusion
2) Loss of clearance between the strands in the See picture 4 in Table 4-4. In wire protrusion,
outer layer of the rope, frequently combined certain wires or groups of wires rise up, on the side of
with wire breaks between or within the the rope opposite to the sheave groove, in the form of
strands. loops. Rope with wire protrusion shall be immediately
discarded.
If there is any indication of internal corrosion, the
rope should be subjected to internal examination as 4.4.5.14 Local increase in diameter of rope
indicated in Figure. Confirmation of severe internal
corrosion is justification for immediate rope discard. See picture 17 in Table 4-4. This condition
usually relates to a deformation of the core such as in
4.4.5.10 Waviness particular environments, a fiber core can swell up
owing to the effect of moisture. If this condition causes
See picture 11 in Table 4-4 for reference. In the
the actual rope diameter to increase by 5 % or more,
case of waviness (see Figure 4-18), the wire rope shall
the rope shall be immediately discarded.
be discarded if, under any load condition on a straight
portion of rope that does not bend around a sheave or 4.4.5.15 Flattened portions
drum, the following condition is met: d1>4d/3 or
d1>1.1d. See picture 19 in Table 4-4. Flattened portions of
rope which pass through a sheave will quickly
deteriorate and may damage the sheave. In such cases
the rope shall be discarded immediately. Flattened
portions of rope in standing rigging can be exposed to
accelerated corrosion, and shall be subject to
inspection at a prescribed shortened frequency if
Figure 4-18：Waviness retained in service.
4.4.5.11 Basket or lantern deformation 4.4.5.16 Kinks or tightened loops
See picture 12 in Table 4-4. Basket or lantern See picture 18 in Table 4-4. Kink or tightened
deformation, also called “birdcage”, is a result of a will cause imbalance of lay length, which will cause
difference in length between the rope core and the excessive wear, and in severe cases the rope will be so
outer layer of strands. Different mechanisms such as distorted that it will have only a small proportion of its
excessive fleet angle that cause the rope touch the strength remaining. Rope with a kink or tightened loop
flange or the rope running over a “tight sheave”. The shall be immediately discarded.
13
4.4.5.17 Bending 4.4.5.18 Damage due to heat or electric arcing
Bends are angular deformations of the rope Ropes that have been subjected to exceptional
caused by external influence. Rope with a severe bend thermal effects, externally recognized by the colours
will suffer similarly to flattened portions of rope and produced in the rope, shall be immediately discarded.
should be treated as in clause 4.4.5.15.
14
Table 4-3: Number, reached or exceeded, of visible broken wires in single-layer and parallel-closed
1
ropes working in steel sheaves, signaling mandatory discard of rope
Rope category Number of load –bearing Number of visible broken wires4
Number wires in all Mechanism group of M1~M4 Mechanism group of M5~M6
2 3
RCN outer strands of the rope in rope over a length of 5
in rope over a length of
(n) 6d 30d 6d 30d
01 n ≤ 50 2 4 4 8
02 51≤n ≤ 75 3 6 6 12
03 76 ≤ n ≤ 100 4 8 8 8
04 101 ≤ n ≤ 120 5 10 10 20
05 121 ≤ n ≤ 140 6 11 11 22
06 141 ≤ n ≤ 160 6 13 13 26
07 161 ≤ n ≤ 180 7 14 14 28
08 181 ≤ n ≤ 200 8 16 16 32
09 201 ≤ n ≤ 220 9 18 18 36
10 221 ≤ n ≤ 240 10 19 19 38
11 241 ≤ n ≤ 260 10 21 21 42
12 261 ≤ n ≤ 280 11 22 22 44
13 281 ≤ n ≤ 300 12 24 24 48
21 4- strand ropes，n ≤100 2 4 4 8
3、4- strand ropes，
22 2 4 4 8
n ≥100
23 At least 10 outer strands 2 4 4 8
1: Above values may also apply to ropes working in sheaves that are exclusively made of a polymer in
combination with multi-layer coiling. They do NOT apply to ropes working in sheaves that are exclusively
made of a polymer material in combination with single-layer coiling.
2: See ISO 4309:2004(E) Annex E for detail rope category number RCN. Where:
09-Including rope of 6X36WS-IWRC(line contract) / 6xK36WS-IWRC(compacted strands) usually
used for main hoist, trolley and boom hoist.
21~23-Rotation-resistant.
3: Filler wires are not regarded as load-bearing wires and are not included in the value of n. In ropes
having a number of layers of strands, only the visible outer layer is considered in the value of n. In ropes
having a steel core, this is regarded as an internal strand and is not considered in the value of n.
4: A broken wire will have two ends.
5: d=nominal diameter of rope.
15
Table 4-4 Typical examples of wire rope damages

No. Description Picture
Crown wire breaks

1.
Usually caused by fatigue
2. Valley wire breaks
3. Localized grouping of broken wires
4. Wire protrusion
16
5. Core protrusion-single-layer rope
Local reduction in rope

6.
diameter-sunken strand
7. Strand protrusion/distortion
Flattened portion
8.
9. Kink (positive)
17
10. Kink(Negative)
11. Waviness
12. Basket deformation
13. External wear
14. External corrosion
18
15. Internal corrosion
Protrusion of inner rope of

16.
rotation-resistant rope
Local increase in rope diameter due

17.
to core distortion
18. Kink
19
19. Flattened Portion
 In case of wire rope abnormalities, the maker of the wire rope should be determined. A colored tracer
thread is embedded in the core of the rope. The manufacturer can be found by this tracer thread.
We are using right hand lay ropes on both right and left handed drums
Left hand lay Right hand lay
4.5 Wire rope lubrication

simultaneous bacterial proliferation in the
It has been proven that a well lubricated fiber core. The lubricant also prevents
wire rope will last four times as many deterioration of the fiber core. A rusty rope is
working hours as a non-lubricated wire a liability, since there is no means of visual
rope. inspection, which can determine the
remaining strength of a corroded rope.
Always use wire rope manufacturer’s
4.5.2 Selection of lubricant
recommended lubricant!
The main lubricants for wire ropes used in a
4.5.1 Importance of lubrication container terminal are below:
The importance of periodic lubrication will never 1) Grease: Mainly is lithium soap base grease.
be overstressed. Mainly they are: Sometimes are mixed with mineral oil for
better penetrability.
1) A wire rope is a machine, having many
moving parts. Each time a rope bends or 2) Special lubricant for rope such as : ESSO
straightens the wires in the strands of the SK(semi-liquid), FUCHS Ropelife (Grease),
rope must slide on each other. Thus, a film of 3) Special synthetic base oil for rope such as:
lubrication should be present on each Ultrachem Chemlube 812(synthetic ester
moving part. When exposed to the same test base oil), synthetic ester base oil supplied by
condition a well-greased rope showed four PAO.
times as many working cycles as a
non-greased rope. The grease that is one kind of protection of
coving to rope may be most wildly used for the
2) A second important reason for lubricating lubrication of the rope traditionarily because of
the wire rope is that it keeps away moisture convenience for using, economical efficiency and
which can cause interior corrosion under efficiency also good effectiveness. Compared to the
20
lubrication oil that is liquid and has better penetrability, uniform coating to the entire length of the wire rope.
the grease are more easily to be tainted with foreign The detail scheme shall be make to assure the full
grains in larger size such as dust, slag or grits. Those length of wire rope can be lubricated. The wire rope
hard grains may also be pushed inside the wire rope may be lubricated by manually or Semi automatically
and cause direct damages to rope. On the other hand, or automatically. The typical manual lubricating is
Oil lubrication also has better performance in resist the shown in Figure 4-19.
moisture, salt spray for the interior of rope than grease
A semi automatic method is shown in Figure 4-20.
lubrication. Additionally grease lubrication is also
This method may be more convenient and effective.
making the visual inspection more difficult. Please
The lubricant is easily to go inside the wire rope by the
reference section 2.6.2 for the lubricant used in this
pressed air. Frequent and not too excessive lubrication
crane before it left the factory.
of the wire ropes produces better results than only
Below are some main requirements to the occasional but rich lubrication. As soon as the grease
lubricant of the wire rope used in STS crane: film vanishes in some areas of the wire rope, it has to
be re-greased.
1) Better antioxidant capacity.
Greasing has to be done only when the wire rope
2) The better capacity to insulate the wires
is completely dry. Otherwise, the existing moisture
from moisture and salinity. That means the
will be contained in the rope and the corrosion be
lubrication shall have a strong capacity of
increased from the inside. Used wire rope should be
adsorbing and binding with the wires.
cleaned with a wire brush to remove any accumulation
Usually ester oil has a better performance in of dirt, grit, rust, or other foreign matter. The purpose
Iron-binding capacity, permeability, film strength and is to remove all old lubricant and foreign matter from
water resistant. The user may determine the lubrication the valleys between the strands and from the spaces
according to the actual condition of different terminal. between the outer wires. This gives newly applied
lubricant ready penetrate into the rope.
4.5.3 The method of lubricant
Lubricant may be applied with an oil can, brush

or any effective method. The objective is to apply a
滴油喷油涂油
Figure 4-19：Method of manual lubricating
21
Figure 4-20：：Method of manual lubricating
Table 4-5: Manpower and tools for the inspection

4.5.4 Lubricating of main hoist and trolley towing of main hoist wire rope
wire ropes Description Quantity Notes
Operator 1 With radio
Introduction of wire lubrication below are based on
power
Main
Examiner 1～2 With radio

the method of semiauto pneumatic lubricating. The
Supervisor 1 With radio
procedure is similar if the other methods are used.
Duster cloth several For clean
During the whole procedure, the boom shall be level venire caliper 1 For measurement
and the crane must be in maintenance mode. Chalk/tape 1 For marking
Inspecting
The necessary manpower and tools are shown in 1 For recording
Tools
form
Table 4-5.
Pen 1
Lubricant
1
tools
Air pump 1
22
1) Ensure that the boom is lowered and the crane boom hoist ropes are below:
is in Maintenance Mode.
1) Boom shall be level and crane shall be in
2) Move the trolley to the suitable position such maintenance mode.
as boom tip so as to utilize the max distance of
2) Operate boom in the boom operation cabin.
trolley travel.
3) Clamp the lubricator onto the rope above the
3) Select a proper position to start the lubricating
landside trolley girder support beam near the
such as drum. Parts of the rope can be
machinery house. See ① in Figure 4-21. Turn
lubricated by rotating the drum slowly. Trolley
on the lubricator and hoist the boom to
is also a necessary good position to lubricate.
maintenance position at slow speed.
Most of the remaining rope can be lubricated
by moving the trolley slowly. There are always 4) Clamp the lubricator on the lead-line rope just
some dead ropes that could not reach on trolley landside of the sheave group on the top cross
or can not go into the drum. You have to tie beam of A-frame which leads to drum, and
manually lubricate it by the bushes with connect the lubricator air hose to the air quick
extension rods. Anyway, the full length of the disconnect. See ② in Figure 4-21.
rope shall be lubricated.
5) Turn on the lubricator and lower the boom at
slow speed until the freshly lubricated rope is
Danger of falling!
at the waterside of the lubricator.
6) Clamp the lubricator on the rope reeving from

Danger of tripping! 4th sheave (count from the centerline of boom)
on the top cross tie beam to the third sheave
(count from centerline of the boom) on the
Keep hands clear of moving parts! boom sheave group. See ③ in Figure 4-21.
7) Turn on the lubricator and lower the boom to

4.5.5 Lubricating of boom hoist wire ropes the operating position at slow speed.
There are some “dead ropes” between the sheaves 8) The last segment of wire ropes can be
on top of A frame and sheaves on boom tip and could not lubricated as shown in Figure 4-22. Connect
reached by normal access. These ropes are long and very the pneumatic lubricator with long hose in
difficult to be lubricated by the normal methods. To reels. Installed the sleeves of lubricator on the
lubricate those ropes, additional tools listed in Table 4-5. ropes. Then secure all the parts of lubricator
are necessary besides the manpower and tool listed in connected with the sleeves by chain in case of
Table 4-6. falling down during the moving of lubricating
later.
Table 4-6: Additional Tools to lubricate the boom
hoist rope 9) The lubricator is towed with a fiber rope at
Description Quantity Note both ends. The fiber rope goes around a
Fiber rope 140m temporary. One mechanic can pull the rope on
tools
Air hose in the walkway of boom while another mechanic

65m
reels hold other fiber rope at top of A frame, so the
lubricator can move along the last segment of
The recommended procedure to lubricated the
23
the wire ropes slow and then the rope to be 10) The dead wraps on both sides of the drum
lubricated simultaneous. should be lubricated using a brush.
2 3
4
1
Figure 4-21：Operating position for boom hoist rope lubricating
Fiber rope
Aux. sheave
24
wire rope for lubricating
Figure 4-22: The lubricating of “dead rope” of boom hoist
Da ng er o f f a l li ng !
Da ng er o f t r ip p ing !
K eep ha n ds cl ea r o f mo v ing pa rt s !
Description Quantity Notes

4.6 Rope re-reeving With radios. At
least one person is
Manpower
The ropes reach the discard criteria shall be Mechanics 5

qualified as a
replaced by new one. The rope can be changed by the
operator.
rope re-reeving device inside the machinery house.
Supervisor 1 With radios
Please see section for the instruction of this device.
Duster cloth Several For cleaning
The manpower and tools needed for the rope
re-reeving are given in Table 4-7. The wire rope type Chisel 1
and size are given in Table 4-8. Reference draiwngs Torque wrench 1
are also given in Table 4-9. One for M16,M20,M24,
Wrench
tools
each size M30, M36

Provided for
Support for reel 1
maintenance staff
Table 4-7：Manpower and tools needed
Rope clamp 5
25
Two chain block Type: Verostar 8.8x26WS-EPIWRC,

2～3t (3t) Grade 1770N/mm2
5 Trolley
chain block for boom hoist Dia: 22mm
towing rope
rope changing Min Break load: 360.6KN
Round and 80mm Length: 395m 2/crane
Wood pad 1
in diameter Type: Verostar 8.8x26WS-EPIWRC,
Rubbers, Catenary Grade 1770N/mm2
wood plate, Several trolley wire Dia: 12mm
snap block ropes Min Break load: 107.3KN
Secure the wire, Length: 160m/185m both 2/crane
plate, slap block,
Wires,steel plate Several
or tightening rope Table 4-9：Reference drawings
end. Description Note
Grinder or rope J474A1500 Rope re-reeving system
1 Cut wire rope
cutter WRR04A-J474A Rope re-reeving device
To colligate rope J607A2000 Main hoist rope reeving system
pincers 1
end Trolley towing rope reeving
Connect the old J607A2100
Chinese fingers 1 system
and new ropes J607A2300 Boom hoist rope reeving system
electric welding Welding Catenary trolley rope reeving
1 J607A2200
machine temporize parts system
Chalk/
1 For marking
punched tape
Barricade the area under the crane where
Note book and
1 For marking falling parts or rope may harm person and
pen
vehicle. Don’t allow the person other than
Drawings and
concerned to enter the procedure area.
instructions of 1 set
re-reeving
Keep away from suspended loads!
Table 4-8：Rope type and length
Description Note
Danger of falling!
Type: Verostar 8.8x26WS-EPIWRC,
Grade 1770N/mm2
Main hoist
Dia: 30mm
rope Danger of tripping!
Min Break load: 670.6KN
Length: 600m 2/crane
Type: Veropro 8.8xK26WS-EPIWRC,
Grade 1960N/mm2 galvanized Keep hands clear of moving parts!
Boom hoist
Dia:30mm
wire ropes
Min Break load:790.3KN
Length: 1338m 1/crane
26
Pay attention to the rotating direction of

reels! The rotating direction(top of reel)
shall towards the handle of the bind
brake.(match the direction of brake
torque)
4.6.1 Re-reeving of main hoist rope
Figure 4-23: Main hoist rope reeving system ①
27
Industries Co.,Ltd. Chapter 4
Figure 4-24: Main hoist rope reeving system ②
1） Move the reels with new ropes into the machinery 10）Set the touque of motor to the max value,
house by the service crane, and install it on the connect the other side of the old wire rope with the
support of rope re-reveeving device. new rope on the re-reeving reel by the guide pulley
2）Install the empty reels at the same time. too.
3）Lower the boom to the level and move the trolley 11）Adjust the belt brake of the motor, ensure reel
to the parking position, then lower the spreader to the should not slip when oprate.
ground to ensure no tension force on the rope. 12）Turn on the rope re-reeving device to wind the old
（bypass the limit switch of main hoist） rope on the empty reel and wind the new rope on the
4）Retract the cylinder of TLS. hoist drum.
5）Bypass the main hoist encoder, decelerate the rope 13）Continue operating untill there are 4 wraps
to the 10% of the rate speed. remained on the re-reeving reel, and wind all the old
6）Loosen the bolts of main hoist rope clips at the rope on the empty reel.
boom tip, make the ropes go through the guide pulley. 14）Ensure to finish the changing.
7）Operate main hoist device, rotate the drum to 15）Loosen the new wire rope on the reel, roll back the
release the rope untill there are 4 wraps only left on motor to release some ropes on the other real, separate
the drum.（2 wraps each side） the new rope with the old one.
8）Loosen the clips of the old rope that would be 16）Fix the new wire rope on the hoist drum by the
changed. rope clips.
9）Connect the end side of the old wire rope on the 17）Change the other rope by the same way.
empty re-reeving reel by the guide pulley in 18）After finishing operating, reset the ropes and clips
the machinery house. at the boom tips.
28
4.6.2 Re-reeving of trolley towing rope
Figure 4-25:Trolley towing rope reeving system ①
Figure 4-26:Trolley towing rope reeving system ②
1)Move the reels with new ropes into the machinery 2）Install the empty reels at the same time.
house by the service crane, and install it on the support 3）Parking the trolley at the land side positon when
of rope re-reveeving device. change the water side wire rope; parking the trolley at
29
the water side when change the land side wire rope. 11）Turn on the rope re-reeving device to wind the old
4）Extend the cylinder of trolley tession device, and rope on the empty reel and wind the new rope on the
bypass the encoder to decelerate the trolley to the 10% trolley drum.
of the rate speed. 12）Continue operating untill there are 4 wraps
5）Loosen the rope clips between the horizontal pulleys. remained on the re-reeving reel, and wind all the old
6）Choose the trolley wire rope should be changed in rope on the empty reel.
the machinery house. 13）Ensure to finish the changing.
7）Remoove the rope clips on the trolley drum. 14）Loosen the new wire rope on the reel, roll back the
8）Connect the other side of the old wire rope on the motor to release some ropes on the other real, separate
empty re-reeving reel by the guide pulley in the the new rope with the old one.
machinery house. 15）Fix the new wire rope on the hoist drum by the rope
9）Set the touque of motor to the max value, connect clips.
the other side of the old wire rope with the new rope 16）Change the other rope by the same way.
on the re-reeving reel bye the guide pulley too.
10）Adjust the belt brake of the motor, ensure reel
should not slip when oprate.
4.6.3 Re-reeving of boom hoist rope
Figure 4-27: Boom hoist rope reeving system ①
30
Figure 4-28: Boom hoist rope reeving system ②
1） Move the reels with new ropes into the machinery the other side of the old wire rope with the new rope on
house by the service crane, and install it on the support the re-reeving reel by the guide pulley too.
of rope re-reveeving device. 9）Adjust the belt brake of the motor, ensure reel
2）Install the empty reels at the same time. should not slip when oprate.
3）Lower the boom to the level and move the trolley 10）Turn on the rope re-reeving device to wind the old
to the parking position, then bypass the encoder of rope on the empty reel and wind the new rope on the
boom hoist device to decelerate the boom drum to boom drum.
30% of the rate speed. 11）Continue operating untill there are 4 wraps
4）Operate boom hoist device, rotate the drum to remained on the re-reeving reel, and wind all the old
release the rope untill there are 4 wraps only left on the rope on the empty reel.
drum.（2 wraps each side） 12）Loosen the new wire rope on the reel, roll back the
5）Loosen the bolts of boom hoist rope clips. motor to release some ropes on the other real, separate
6）Remoove the boom rope clips at the T-frame. the new rope with the old one.
7）Connect the end side of the old wire rope on the 13）Fix the new wire rope on the boom drum by the
empty re-reeving reel by the guide pulley in the rope clips.
machinery house. 14）After finishing operating, reset the rope clips
8）Set the touque of motor to the max value, connect at the T-frame.
31
4.6.4 Re-reeving of catenary trolley rope
Figure 4-29: Catenary trolley rope reeving system ①
Figure 4-30: Catenary trolley rope reeving system ②
1）Move the reels with new ropes into the machinery with the new rope and empty reel.
house by the service crane, and install it on the support 5）Start motor to extract the old rope and feed the new
of rope re-reveeving device. one.
2）Install the empty reels at the same time. 6）After all old ropes winded to the reel and the new
3）Lower the boom to the level and move the trolley rope go through its route, connect two end sides with
to the parking position. fixed point on catenaery trolley.
4）When change the wire ropes between land side and 7）When change the old rope between land upper beam
water side catenary trolley, remoove the old rope from and the fixed point on trolley, remove the old rope
catenary trolley firstly, and then connect each end side directly and install the new rope by hand.
32
4.7 Rope Type & Size for cranes

Dimension
Length /
Location Type of wire ropes (diameter) of wire Brand name
wire rope
rope (mm)
8.8xK26WS-EPIWRC, Grade 1960N/mm2
Boom Hoist 1338m*1 30 Verope
galvanized
Trolley 8.8xK26WS-EPIWRC, Grade 1770N/mm2 395m*2 22 Verope
Catenery
8.8xK26WS-EPIWRC, Grade 1770N/mm2 160m*2 12 Verope
(Outside)
Catenery
8.8xK26WS-EPIWRC, Grade 1770N/mm2 185m*2 12 Verope
(Inside)
Main Hoist 8.8xK26WS-EPIWRC, Grade 1770N/mm2 600m*2 30 Verope
33
Quayside Container Crane Chapter FIVE
Shanghai Zhenhua Port
Machinery Co. Configuration and Maintenance Manual
Chapter 5 Quayside container crane inspection requirements for high-altitude fall hazard
Quayside container crane is high mechanical misfortune to the family.

equipment. The cranes include many parts. After the Therefore, the inspection of the high-altitude fall
parts are used for a period of time, some hazard source is necessary. Crane maintenance
connections may be loose. That will cause danger of personnel must pay attention to it. Carry out the
falling. Under the crane, there are shuttling crane inspection work in accordance with the following
trucks and staff who frequently access to crane. table and make a record.
Once the part falls from high, it poses a threat to Maintenance personnel can print or copy the
personal safety. If it causes a major accident, it will table below, fill in the date and name before the
cause significant loss to corporation and bring inspection. Pigeonhole them after checking.
Quayside container cranes altitude fall hazards key inspection items

Inspectors Date
Location Item of Inspection Frequency Result Note

1.Bolt connections of boom sheave units; Per 3 months
2.Clamp plates of boom sheave units; Per 3 months
3.Pins of boom sheave units; Per 3 months
4.All the connections of shield(Including pin shaft、split
Per 3 months
pin, support welding and so on);
5.Bolt connections of slack rope limit device; Semiannually
6.Clamp plates of slack rope limit device; Semiannually
7.Pins of slack rope limit device; Semiannually
Seaside A 8. Counterweights' connection of slack rope limit device; Semiannually
Frame 9.All support welding of slack rope limit device; Semiannually
10.Bolt connections of service crane; Semiannually
11.Location pin of service crane; Semiannually
12.The pulley and the back plate of service crane; Semiannually
13.Bolt connections of boom latch hook; Semiannually
14.Clamp plates of boom latch hook; Semiannually
15.Pins' installment of boom latch hook; Semiannually
16. All counterweight's connection of boom latch hook; Semiannually
17. All support welding of boom latch hook; Semiannually
1. Bolt connections of stay bar ass. ; monthly

Stay Bar
2. Clamp plates' connections of stay bar ass. ; monthly
Ass.
3. Pins of stay bar ass. ; monthly
5-1
1.Bolt connections of boom latch support; monthly

2.The connection of boom latch support's buffer; monthly
3.Pins' installment of boom latch support; monthly
4.The connection of anti-slap block of guide support; monthly
5. Bolt connections of boom hoist reeving ass. ; Per 3 months
6. Clamp plate's connection of boom hoist reeving ass. ; Per 3 months
Boom
7. Pins' installment of boom hoist reeving ass. ; Per 3 months
8.All the connections of boom hoist reeving
ass.(Including pin shaft、split pin, support welding and so Per 3 months
on);
Semiannually
9.Bolts and pins of manhole cover;
10.Bolt connections of boom anti-collision device; Semiannually

11.Clamp plates of boom anti-collision device; Semiannually
12.Pins' installment of boom anti-collision device; Semiannually
13.Bolt connections of service crane; Semiannually
14.Location pin of service crane; Semiannually
16.The fix of flood light's cover; Per 3 months *
17.The connection of trolley buffer; Per 3 months *
18.Bolt connections in L/S/T device； Per 3 months **
19.Clamp plates in L/S/T device； Per 3 months **
20.Pins in L/S/T device； Per 3 months **
21. Sheer plates in L/S/T device； Per 3 months **
22. Bears in L/S/T device； Per 3 months **
23. Supports of L/S/T device； Per 3 months **
24. Bolt connections of trolley heaves ass.（includes **
Per 3 months
sheaves, idles & anti-slap blocks）；
25. Pin connections of trolley heaves ass.（includes **
Per 3 months
sheaves, idles）；
26. Clamp plates of trolley heaves ass.； Per 3 months **
27. Bolt connections of catenary trolley heaves ass. **
Per 3 months
（includes sheaves, idles & anti-slap blocks）；
28. Pin connections of catenary trolley heaves ass. **
Per 3 months
（includes sheaves, idles）
29. Clamp plates of catenary trolley heaves ass.； Per 3 months **
Boom Hinge 1. The bolt connections of boom hinge ass. monthly

Ass. 2. Clamp plates of boom hinge ass. ; monthly
5-2
3.The cuneal plate of upper hinge support; monthly

4.The cuneal plate of lower hinge support; monthly
5.The bolt connections of trolley stop; Per 3 months
6.Clamp plates of trolley stop; Per 3 months
7.Pins of trolley stop; Per 3 months
8.The wire rope of trolley stop; Per 3 months
9. The fixation of seal gate of boom and girder near the
Semiannually
hinge ass. ;
10. The fixation of hand-hole cover on boom and girder
Per 3 months *
near the hinge ass. ;
11.The bolt connections of idle ass.(includes main hoist、 **
Per 3 months
trolley、catenary trolley) ;
12.The pins of idle ass.(includes main hoist、trolley、 **
Per 3 months
catenary trolley) ;
13.The supports of idle ass.(includes main hoist、trolley、 **
Per 3 months
catenary trolley) ;
1.The connection between girder and machinery

house(including bolt, pin and support welding and so Per 3 months
on) ;
2.The connection of trolley buffer; Per 3 months
3.Bolts and pins of manhole cover; Semiannually
4.The fixation of hoisting hole cap of machinery house; Semiannually
5.The connections of all peripheral appendix of Semiannually
machinery house (including door, window, ventilation
fan, nameplate and so on);
Semiannually
6.Bolt connections of service crane;
Girder 7.Location pin of service crane; Semiannually

9.The fixation of flood light's cover; Per 3 months *
10.Bolt connections of snag protection device; Per 3 months **
11.Clamp plates of snag protection device; Per 3 months **
12.Pins of snag protection device; Per 3 months **
13.Sheer plates of snag protection device; Per 3 months **
14.Bears of snag protection device; Per 3 months **
15.Supports of snag protection device; Per 3 months **
16.Bolt connections of trolley tension device; Per 3 months **
17.Clamp plates of trolley tension device; Per 3 months **
18.Pins of trolley tension device; Per 3 months **
5-3
19.Sheer plates of trolley tension device; Per 3 months **

20.Bears of trolley tension device; Per 3 months **
21.Supports of trolley tension device; Per 3 months **
22.Bolt connections of catenary trolley tension device; Per 3 months **
23.Clamp plates of catenary trolley tension device; Per 3 months **
24.Pins of catenary trolley tension device; Per 3 months **
25.Sheer plates of catenary trolley tension device; Per 3 months **
26.Bears of catenary trolley tension device; Per 3 months **
27.Supports of catenary trolley tension device; Per 3 months **
1. All rigid clamp and the flexible clamp of trolley rail; monthly
Trolley Rail 2.The installment of cuneal plate near short rail; monthly
3.The fix of rail pad; monthly
Festoon 1.Bolt connections of festoon rail; monthly

2.The welding of supports of festoon rail; monthly
3.The connection of festoon rail near boom hinge joint
monthly
(including bolt, vertical bar's welding and so on);
4. All relative part of festoon sys(including to tow trolley,
monthly
cable fix and so on);
1.The bolt connection between seaside upper beam and

Per 3 months
legs;
2.The bolt connection between landside upper beam
Per 3 months
and legs;
3.The bolt connection of fixed tie links; Per 3 months
4.The bolt connections of HV cable reel; Per 3 months
Frame 5.Pin of HV cable reel; Per 3 months
6.Clamp plates of HV cable reel; Per 3 months
7.The fix of windproof strips (including bolt, steel wire
Per 3 months
and so on);
8.The fix of nameplate on horizontal beam; Semiannually
Semiannually
9.Bolts and pins of manhole cover;
1.Bolts connection of trolley horizontal wheel; monthly

2.All bearing of trolley horizontal wheel; monthly
Trolley 3.All support welding of trolley horizontal wheel; monthly
4.Bolts connection of operator's cab; monthly
5.Bolt connections of cab suspending brackets; monthly
5-4
6.Pins' installment of cab suspending brackets; monthly

7.Clamp plates of cab suspending brackets; monthly
8.The buffer of cab suspending brackets; monthly
9.Bolt connections of trolley anchor device; monthly
10.Pins' installment of trolley anchor device; monthly
monthly
11.All supports' welding of trolley anchor device;
12.Bolt connections of spreader cable reel; monthly

13.Pins' installment of spreader cable reel; monthly
14.Clamp plates of spreader cable reel; monthly
15.The cuneal plates of spreader cable reel; monthly
16.The installment of bearing of spreader cable reel; monthly
17.The chain wheel connection of spreader cable reel; monthly
18.Bolt connections of MH stop limit switch; monthly
19.Pins' installment of MH stop limit switch; monthly
20.The clamp of wire rope of MH stop limit switch; monthly
21.Bolt connections of main hoist sheaves; monthly
22.Pins' installment of main hoist sheaves; monthly
23.Clamp plates of main hoist sheaves; monthly
24.The connections of all peripheral appendix of
operator cab(including door, window, rear view mirror, air
Per 3 months
conditioning support, ventilating fan, floor window,
window safety bar, rain shield and so on);
25.Bolt connection of trolley drive device; monthly *
26.Pins connection of trolley drive device; monthly *
27.Clamp plate connection of trolley drive device; monthly *
28.The cuneal plates of trolley drive device; monthly *
29.Bearings of trolley drive device; monthly *
30.All supports welding of trolley drive device; monthly *
31. The bolt connections of idle ass. ; monthly **
32. The pins of idle ass. ; monthly **
33. The bolt connections of trolley equalized sheaves; monthly **
34. The pins of trolley equalized sheaves; monthly **
35. The bolt connections of trolley wheels; monthly **
36. The pins of trolley wheels; monthly **
37. The bears of trolley wheels; monthly **
38. 11.The connection of trolley buffer; Semiannually **
Spreader & 1.Bolt connections of spreader and headblock; monthly
5-5
Headblock 2.Pins' installment of spreader and headblock; monthly

3.Clamp plates of spreader and headblock; monthly
4.Cuneal plates of spreader and headblock; monthly
5.The bearings of spreader and headblock; monthly
6.Bolt connections of main hoist sheaves; monthly
7.Clamp plates of main hoist sheaves; monthly
Stairs, 1. All fixed hook joints of platforms; Per 3 months

Ladders & 2.Bolt connections and welding of stairs; Per 3 months
Platforms 3.Bolt connections and welding of ladders; Per 3 months
1. The whole inspection of hydraulic sys. and lubrication

Hydraulic Per 3 months
sys. power station(including fastener and so on);
Sys. &
2. The fixation of pipeline of hydraulic sys. and
Lubrication
lubrication sys. (including pipe, clip, oil nipple and so Semiannually
Sys.
on);
Electric Sys. 1. The bolt connections of electric sys. ; Per 3 months

2.The mounting of the cable-slot cover, junction boxes
Per 3 months
and limit switch;
3.Check the fastener of walkway lights ,floodlights, etc.; Per 3 months
Addition
Item
Note：
1. The inspection requirement refers to the drawing. Insure the welding、bolts、pins meet the design
requirement.
2. The inspection of potential falling hazards not only includes the above items .Other items can be
added during the checking process.
3. The inspection of potential falling hazards is a special requirement. It can not be replaced by routine
inspection.
4. “ * ”refers to the application for MOT cranes; “ ** ”refers to rope driven cranes; not marked items are
shared by these two kinds cranes.
5-6
Quayside Container Crane Chapter SIX
Chapter 6 Instruction for Drawing No.
Drawing No. is the basic information subsidiary relation between assembly and
code and foundation of product designing for parts；
the company. It is also the basic of enterprise
6.2 The explanation of ZPMC drawing no.
informatization data.
label
6.1 Drawing No.'s characteristics 6.2.1 There is a title bar at the lower right
6.1.1 Exclusive. It means one drawing no. corner of every drawing. There is
represents only one product, or assembly, drawing no. and drawing name of
or part. assembly or part on it.
6.1.2 Affiliation. It can show the
Diagram of title bar

6.2.2 Instruction for drawing no.
J607A 04 01 03
(4) Third layer subassembly/component No.，03 denotes “riffled

plate” of trolley base frame assembly.
(3) Second layer subassembly/component No. ， 01 denotes
“trolley base frame” of trolley drive device.
(2) First layer part/ component No.，04 denotes “trolley drive
device” of J607A.
(1) Product sort No.，J607A denotes this project Container Crane
6.2.3 J607B SPRC Container Crane subsidiary list is as following:
6-1
Quayside Container Crane Chapter SIX
No. Drawing No. Drawing Name

1 J607B0000 总图 General arrangement
2 J607B0100 钢结构总图 Structure general arrangement
3 J607A0200 小车总成 Trolley assembly
4 J607A0300 主起升机构 Main hoist mechanism
5 J607A0400 小车驱动机构 Trolley drive mechanism
6 J607A0500 俯仰机构 Boom hoist mechanism
7 J607B0600 大车行走机构 Gantry drive mechanism
8 J474A1000 挂舱倾转装置 Anti-snag and tilt device
9 J607B1200 吊具上架 Headblock
10 J607B1300 吊钩横梁 Cargo beam
11 J474B1400 应急装置 Emergency drive device
12 J474A1500 换绳装置 Rope re-reeving device
13 J607B1600 室内维修行车 Machinery house service crane
14 J607A2000 起升缠绕系统 Main hoist rope reeving system
15 J607A2100 小车缠绕系统 Trolley rope reeving system
16 J607A2200 托架小车系统 Catenary trolley rope reeving system
17 J607A2300 俯仰缠绕系统 Boom hoist rope reeving system
18 J607B3000 机器房 Machinery house
19 J607A3100 司机室 Trolley operator's cab
20 J474A3200 俯仰操作室 Boom hoist operator's cab
21 J607A4000 高压电缆系统 High voltage power supply system
22 J607A4100 小车电缆输送系统 Trolley cable conveying system
23 J607B5000 梯子平台 Walkway, stair, platform and ladder system
24 J607A5100 电梯 Personnel elevator
25 J607A6000 大车锚定 Gantry stowage pin assembly
26 J607A6200 大梁锚定装置 Boom stowage device
27 J607A6300 大梁防撞装置 Boom anti-collision device
28 J607A7000 空压机系统 Compressed air system
29 J607A7100 室外维修行车 Outdoor service crane
30 J607B7200 润滑系统 Lubrication system
31 J607B7300 铭牌 Nameplate
32 J607A7400 限位系统 Crane limit switch system
33 J607A7600 整机消防系统 Water piping system
6-2
Quayside Container Crane Chapter SEVEN
Chapter 7 Safety
Safety is a priority either in operation or in the crane safety procedures described in this
maintenance and inspection. This chapter informs chapter.
you of the possible hazards and necessary
precautions to be taken when operating or 7.1 WARNINGS AND SYMBOLS
maintaining the crane.
The following signs and symbols are used in the manual
Before the operation or maintenance of cranes, to designate instructions of particular importance.
maintenance or repair personnel must carefully
read and thoroughly understand and strictly follow
Symbol Description Symbol Description

Special information and/or orders and
prohibitions directed towards Hazardous voltage
preventing damage.
Warn of electric voltage. Keep hands and body clear
Stay clear No standing on it
Keep hands clear of the moving

No access
parts.
Do not enter, Authorized personnel

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

manual. efficiency
Keep away from suspended loads

Crush hazard
Refers to information in other parts

Additional Information
of the Manual
Wear protective clothing

Danger of tripping
7-1
In this manual, as well as on the crane, warnings or warning signs are categorized into four levels according to the
severity of danger (or seriousness of accident) as shown in Table7.1-1.
Table 7.1-1
Warnings Definitions
Refers to imminently dangerous situations. Used when serious injury or even
DANGER
death will occur if specified procedures or instructions are not followed.
Refers to potentially dangerous situations. Used when serious injury or even
WARNING
death might occur if specified procedures or instructions are not followed.
Refers to potentially dangerous situations. Used when medium or slight injury
CAUTION will occur or when the machine or equipment will be damaged if specified
procedures or instructions are not followed.
NOTE Used when attention must be paid to or when information must be stressed.
7.2 GENERAL PRECAUTIONS that may release any form of hazardous energy including,
but not limited to, electrical, rotational, mechanical,
This crane embodies the latest and the best in structural, chemical, hydraulic, or pneumatic energy, while the
electrical, mechanical, and hydraulic systems and may equipment is shut down.
only be put into operation by qualified or trained staffs.
In addition to the operation and maintenance instructions
Before operating or maintaining the crane, the operation provided herein, legal （ generally valid ） and other
and maintenance instructions have to be read carefully obligatory regulations issued by the local authorities for
and understood by all maintenance and repair personnel. accident prevention and environmental protection must
also be observed.
This machine is also built according to the latest
standards of technology and recognized safety technical It is our admonition that working cautiously and carefully
rules, and is equipped with safety devices. It has been is the best protection from accidents.
checked for function and safety before delivery and
hand-over. However, in case of faulty operation, misuse, None of us has all the expertise or training needed to
or use not in accordance with the instructions, dangers complete every repair that may be required. Do not try to
and/or damages could still arise and threaten the health of undertake a task on which you are lack of training or
the operation personnel or third persons, the container qualifications.
crane or other material, and/or the efficient operation of
the crane itself. IT’S ABOUT YOUR SAFETY!
Always use safety harnesses and/or other safety gear as

required whenever in an elevated working place. It is The manufacturer, Shanghai Zhenhua Heavy
always a good practice to work in a team of at least two Industries Co. LTD. (ZPMC), has tried his best to
persons in a place where potential dangers may arise. assemble and make available a complete set of
instructions in the form of manuals and data sheets
It must be observed strictly to secure the proper to provide all necessary information for crane
protection of staff whenever working on an equipment operation and maintenance. In case of uncertainties,
7-2
problems and additional requests, we will always be instructions are not permitted for the sake of safety
at your disposal. Please do not hesitate to contact our technical.
local representative and/or technical supporting
staffs at the manufacturing base: All maintenance and repair work must undergo a
thorough review and inspection to ensure effective.
7.3 GENERAL RULES OF CONDUCT AND
SAFETY REGULATIONS IMPORTANT SAFETY PRACTICE!
The crane may only be operated in technically healthy

condition and in compliance with the operating and The following safety rules must be observed strictly in
maintenance instructions. Particular malfunctions that practice:
may impair the safety must be eliminated immediately.
Before each commissioning, the crane must be checked (1) Verify that there is no danger to other related
for operational safety! personnel before operating the machine.
Uncompleted or illegible operation and maintenance must (2) Do not touch the rotating parts or the moving parts of
be replaced immediately. the machine during operation.
Protection and safety devices (covers, safety barriers, etc.) (3) Do not perform inspection and adjustment of the
must not be removed while operating the unit. The crane machine during operation.
must not be operated without safety devices at any time.
(4) Do not touch the live parts inside the control cabinets
Appoint personnel solely responsible for the crane or terminal boxes. The internal live parts carry high
operation and maintenance respectively. Also, do not voltage current and pose the risk of electric shock
permit unauthorized personnel to operate the crane. when touched.
The operating and maintenance staff has to be checked by (5) Do not lubricate the components of the machine
the employer responsible for the operation. The person during operation.
responsible for the operation is obliged to operate the
crane only in proper condition and to instruct the (6) Immediately press the emergency stop pushbutton to
operating and service staff to wear protective clothing, etc. stop the machine when an accident has occurred or is
whenever necessary or required by the regulations. likely to occur.
If there are any alterations concerning the safety of the (7) Always keep the machine and it’s surroundings clean.
machine or changes in the operational behavior, the Especially Keep the passageways at the elevated
machine has to be set to a standstill and the fault has to be place clean so that personnel can walk safely.
reported to the relevant authority or person. Damages
affecting the safety or malfunctions at the crane have to (8) Warn all the service personnel of an unsafe intended
be eliminated immediately. action that may endanger them.
Arbitrary constructive modifications and the alteration of (9) Report any injury and make sure the wounded person
parameters beyond the operating and maintenance can receive fast medical treatment.
7-3
tie-down.
(10) Installed in the safety device, no special
circumstances shall not remove installed; often fully (13) Daily inspection of the crane is to maintain the crane
check the operation of each safety device is complete, operate in the best state. You must always check the
the role of ability to meet the requirements of various mechanical action status, the wearing of the various
devices. components, oil supply situation. Through routine
inspections, if find any imperfections, take measures
(11) Measures should been taken to prevent crane moving immediately to repair so as to make it in the
when sudden wind occur during operation. Each optimal state.
driven wheel should been equipped with wheel brake.
During operation, when the gantry motor brake 7.4 SAFETY RULES FOR OPERATION
action, wheel brake delay action. If the wind speed
has reached more than 20m / s, the wheel brake Pre-service Precautions:
automatic act. The wheel brake should meet the
requirements that when the air pressure reach 551.7N (1) Before starting work at the crane, all persons have to
/ m (wind speed of 30m / s), the crane still will not be instructed in theoretic and practical use of
move However, if the wind speed is predicted to emergency measures in case of an accident, the use
remain more than 20m/s for a long time, or in case of the emergency exits, and the use of rescue aids
of a storm, it must be fixed according to item (12). (fire extinguishers).
When the wheel brake action, since the limit switch
and gantry motors are controlled by electrical (2) Unauthorized persons should not enter the crane.
interlock, you can not start gantry device. In addition,
after the container handling operation, stop the crane (3) All safety devices and facilities with protection
by wheel brakes. functions must always be connected and operable.
They must not be rendered ineffectively or used
(12) The measures should be taken in the case of Storm. improperly.
Storm means the heavy wind whose speed is more
than 20m / s winds for a long time. In order to (4) The factory setting of the components must not be
prevent the move of the crane when in storms, or changed.
when predict to the possibility of this phenomenon,
we must take advantage of the seaside and the (5) Observe the inspection procedure stated in this
landside anchor device and tie-down to fix the crane manual for the inspection of each component.
onto the foundation. The anchoring device and
fastening can ensure that the crane does not move (6) Make sure no irrelevant items collide with the crane,
when the air pressure reaches 1854.3N / m (i.e. wind or are within the walking range of the crane. If there
speed of 55 m / s)as the boom is up. Anchoring is such a situation, it is necessary to quickly move
device located under the seaside beam and land beam. these items.
Anchoring device is same as wheel brake and
tie-down, it electrical interlock with the gantry (7) Confirm whether the anchoring device, the fastening
device. So before running the crane must release the devices are in a working state. Because the
anchoring device firstly. If the crane won’t run for a anchoring device, tie-down and gantry motor
long time, fix the crane with anchoring devices and interlock, when they are in working condition the
7-4
crane is unable to walk. (5) Always operate the crane smoothly to prevent the
shock of start-up or stoppage. Avoid operations such
(8) Check if the oil supply for the mechanical devices is as abrupt loading or unloading at full speed with
sufficient. excess load or unnecessary repetition of start-up or
stoppage.
(9) Check whether the switches and joystick of electric
device are on the right position. (6) When the crane encounters a strong wind over 31m/s,
conduct the crane stowage procedure against wind.
(10) Check whether the power and voltage are normal.
Precautions after service:
(11) Unlock the boom which is locked by boom storage
device. Put it down to the working position(namely (1) Stop the crane at the registered position.
level position).
(2) Stop the trolley at eh registered position (namely the
(12) Run the crane under unloaded condition. Check the stop position).
action of safety devices and limit switches are
normal.
(3) Raise up the boom and lock it by boom stowage
Precautions during service: device. When the boom is hocked, the light in the
operator’s cab will be on.
(1) Do not step into an area below the cargo lifted when
the crane is operating. It may result in a critical (4) Return the joystick in the operator’s cab and
accident. switched to the registered position.
(2) The lifting load and the reach during the loading or
unloading operation must be within the limit values (5) Return control cabin’s switches in the machinery
defined by the specifications of the crane. Excess house back to the “OFF” position.
reach or excess load may result in a critical accident
such as a fall-down, a break-down or a damage of (6) Check if wheel brakes are in working condition.
the crane.
(3) Immediately stop operating the crane when an (7) when predict to the possibility of strong storm, or the
abnormal sound or vibration arises. Inform the crane will stop for a long time, take advantage of the
responsible personnel immediately to eliminate the seaside and the landside anchor device and tie-down
malfunctions or conduct maintenance. to fix the crane onto the foundation.
(4) Do not leave the crane with open hatch covers, or (8) To assure keeping good condition for next operation,
other openings into which a person could step or check if the oil supply for the mechanical devices is
tools and objects could fall. And do not leave sufficient.
lubricants, paints, or other materials uncovered or
un-attended. (9) Check and repair the imperfection of devices.
7-5
(10) To prevent irrelevant person from entering the

machinery house and operator’s cab, equipped locker Observe the following safety rules when conducting
for these two places. maintenance or inspection work on the crane:
(11) Check whether the flight light on the boom and apex (1) Personnel unauthorized by the person responsible for
beam are on. the crane should not perform maintenance or
inspection work.
Quay foundation:
(2) Do not perform maintenance or inspection work
(1) The foundation is the most important part for the when the crane is operating.
normal operation. After a long period of use, due to
the sinking and moving of the foundation, such (3) Before conducting maintenance or inspection work,
phenomena as horizontal error may occur. So cut off the main power supply and all the power
regularly check the dimension of the foundation. If resources; then verify if the crane is stopped
exceed the allowable value, you must adjust the completely.
basis.
(4) Performing maintenance or inspection work before
(2) The rail should remain straight. Adjust the height the release of the energy stored in all the relevant
difference of the connecting joint to the minimum. In system. This also includes putting the spreader and
addition, after long-term use, bolts may be loose, if head block on the dock, put down the boom so that it
so, must fasten them immediately. supported by the forestay or arise the boom to the
maintenance position and lock it.
DANGER ZONE MUST BE BLOCKED BY
SUITABLE MEASURES. HAZARD AREAS
(5) Before conducting maintenance or inspection work,
MUST BE INDICATED PERMANENTLY
warn all the related workers of the work and prohibit
BY CLEAR INDICATIONS, SUCH AS
entry of those unauthorized workers into the
COLORED SIGNS OR WARNING SIGNS.
maintenance and inspection areas.
7.5 SAFETY RULES FOR MAINTENANCE (6) The crane should be in maintenance mode for such a
AND REPAIR task.
The maintenance work is different from the ordinary (7) Secure the repair area by closing a wider area. During
operations. When the crane is under maintenance, some the maintenance of the crane, be sure to close hatches
of its parts may be disassembled or unstable, thus special on the machinery house and other places, or protect
attentions should be paid to. them with fences.
BEFORE COMMENCEMENT OF
(8) When inspecting one of the cranes on the same
SERVICE WORK THE CONTAINER
gantry rails, attach the mechanical stoppers or station
CRANE HAS TO BE MADE FREE OF
a person to prevent collision of the cranes.
LOAD, SET TO MAINTENANCE
POSITION AND SWITCHED OFF, IF NO
(9) Never fail to close the door to the walkways and the
OTHER NOTE IS GIVEN.
7-6
chains at the gate of the walkways. (19) After the maintenance/repair work, update the fault
log and the maintenance check list.
(10) When removing bolts, pins, wire ropes, and cables,
warn workers other than the service personnel of the (20) Do test running and functional check of the
danger of attached parts falling. components and safety devices before starting the
operation and service again.
(11) When relieving the residual pressure of the
trim/list/skew and rope tensioning device, warn
maintenance personnel of the device. The sheaves 7.6 CONDUCT IN CASE OF ACCIDENTS
may move and each wire rope may loosen due to the AND EMERGENCY
relief of the pressure of the hydraulic cylinder. It may
cause injury. (1) All personnel must be trained and familiar with in
particular emergency response procedures and
(12) Verify that there is no residual pressure left in the incident response procedures. Employers should
hydraulic equipment and the compressor. Residual ensure that the version of the above procedures and
pressure may cause injury. training is latest.
(13) If hands will be on the rope for inspection, they must (2) In the case of an accident with injury to persons,
be away from the pinch point. damages to devices or other materials, immediately
inform the supervisor after providing the injured
(14) The maintenance persons should pay more attention with first aid. For well-directed rescue efforts,
to the moving/rotating parts. clearly give the degree of severity of the injury to
persons and the damage to property.
(15) Do not use the machine parts as climbing aids.
(3) In case of disasters (e.g. fire), all persons must leave
(16) Reinstall and test safety devices (which have been the crane using the indicated emergency exits and/or
disassembled during the assembly or test and repair other facilities.
work) immediately after the end of the maintenance
and the repair work. (4) Rescue actions may only be carried out by instructed
operating and rescue personnel. Use the intended
(17) Correctly tighten the screw joints that were loosened protective equipment.
during the test and the maintenance work.
(18) Replace the fastening elements and seals (e.g. (According to the calculation, this project have no need to
self-securing nuts, washers, split pins, O-rings and set tie-down device )
seals) which cannot be used again.
7-7
Shanghai Zhenhua Port Quayside Container Crane
Machinery Co.
Configuration and Maintenance Manual Chapter Eight
Chapter 8 Maintenance guide of the anticorrosion coating in port machinery
equipments
As to port machinery equipments, the function of time etc. If exterior hidden disasters can not be eliminated
anticorrosion coating is not simply beautiful visually，but in time, which will accelerate wearing down the coating
also which will protect steel structures out of natural and shorten anticorrosion life. Therefore, users should
corrosion. The anticorrosion capability of the exterior strictly execute the maintenance work in the process of
coating has very important effect on assuring the most using the Port machinery equipment, assuring the best
durability of port machinery equipments. anticorrosion capability of coating.
8.1 General principles
ZPMC provide the certified painted production,
which is designed according to the durability and 8.1.1 Scope
considering the natural corrosion of coating in the This guide is applied to daily maintenance of
correlative environment conditions provided by buyers. anticorrosion coating in the process of using the Port
Reasonable application and coating system can actually machinery equipments.
assure the coating of steel structures to possess suitable 8.2 Standard comparison of coating rust
anticorrosion function and life. While some undefined
Rust is corrosion from substrate to surface, as
factors will dramatically restrict the durability of
follows is European scale of degree of rusting for
anticorrosion coating, such as without repairing coating
anticorrosive paints standard comparison：
damages and cleaning the grease of coating surface in
The below table shows rust areas percent according to rust grades：
grades Rust areas percent
Re1 0.05%
8-1
Machinery Co.
Re2 0.5%
Re3 1%
Re4 3%
Re5 8%
Re6 15~20%
Re7 40~50%
Note: when somewhere rust grade is more than Re4 or the single rust area is bigger than 0.25 square meters, the owners
need to remove the rust and repair the coating. When the most scale of rust areas of Port machinery equipment is Re4,
owners should remove rust and repair for the whole machine.
8.3 Inspection period and content of daily the main contract.

8.3.2 Inspection content and measurement
maintenance
Inspection content is generally inspecting
8.3.1 Inspection period coating surface of the whole machine, including
8.3.1.1 Inspection of coating in warranty period：After inspection of surface cleanliness (grease and other
delivering the Port machinery equipment, owners contamination), surface salt deposit, surface water,
should generally inspect the coating surface of local surface coating damage and some coating
Port machinery equipment every year. appearance etc, owners should take protective
measurements for the different defects.
8.3.1.2 Inspection of coating after warranty period：In
order to assure the continuing effective 8.3.2.1 Inspect and deal with the contamination of
anticorrosion coating capability, in the first half coating surface
of the year of equipment coating warranty period
expiration, owners should invite experts to 1) If the Port machinery equipment is
evaluate anticorrosion effect for coating of the contaminated by grease, dust and other
whole machine, and take corresponding contamination, the accumulation will directly
measurements to assure anticorrosion effect damage the coating. If there are black or yellow
according to evaluation results. We advise adhesive objects, whose source should be
owners to inspect the whole machine surface inspected, then measurements should be taken to
condition once half a year after the warranty prevent contamination from increasing to
period. continue, and surface contamination should be
8.3.1.2 If small local paint damage was found during cleaned out by using cleanliness agent.
crane inspection, users should take the initiative
in repairing in accordance with the Note: The long-term accumulation and cover of grease
corresponding paint repair procedure to avoid contamination will easily cause the whole coating
damaging range widening. Even during the damage.
paint warranty period of crane manufacturer, the
manufacturer should not be deemed to take the 2） If there is much dust or corrosive salts
responsibility of those small local damage covered the surface of steel structure, the owner
produced after handover, unless it is specified in should remove them by high-pressure water, the
8-2
Machinery Co.
pressure is not less than 2000psi. the equipment is used for a time. The direct
sunlight for a long time transforms the coating
8.3.2.2 Inspections and treatments of salt deposit of into powders or particles, it is a natural
coating surface phenomena of coating attenuation.
Salt deposit of coating surface can 8.3.2.6 Inspections of paint color fading
accelerate the loss of coating, so please
immediately clean it out by water when you find It will be fading after the coating suffers
a layer of white powder deposit. from the erode-corrosion of ocean climate, the
consistent exposure and the high heat and
8.3.2.3 Inspections and treatments of the waterlogging humidity of beach sunlight for a long time. So it
on coating surface is normal that port machinery equipment is
operating after a long time.
During the operating, some drain holes may
be jamed up, so that results in some places 8.3.2.7 Inspections of the coating of galvanized steel
waterlogging occurs. The waterlogging of surface
coating surface can accelerate corrosion, so the
anti-corrosion life of coating will be shortened. Galvanized steel has a good anti-corrosion
Please inspect the state of the waterlogging on performance. Zinc coating plays a nice role on
coating surface regularly, and dredge it in time. protecting steel through sacrificing anode,
because the potential of zinc is lower than steel.
8.3.2.4 Inspections and treatments of local damage of For the whole beauty, some galvanized parts
coating such as handrails are also painted. But the
adhesive force of the coating on the galvanized
It is inevitable to collide or abrade during parts is less than the steel, so it may be peeled off
the operating, which makes the coating damaged. after a long time. There is no need to be
These coating damages must be repaired repainted when the red rust on the zinc coating.
according to the repair standard regardless of Because which indicates that substrates have not
whether the collision and abrasion damage the be eroded.
substrate of steel structure. During inspections,
once found the coating is damaged, please pay 8.3.2.8 Inspections of the coating on stainless steel
attention to the coating damaged by blunt object.
The coating scratches are not obvious, but the Stainless steel is a material of corrosion
local peeling and loose phenomena may have resistance, so it is not rusted in general. But some
happened. Therefore, these damages should be easy-rusted contaminants such as iron scraping
timely removed during repairing to avoid attached to the surface of stainless steel would
substrate corrosion. Coating damaged places make the stainless steel surface rust. The owner
must be repaired in time to avoid expanding the can remove the rusts by power tools or sandpaper
rust zone because of exposed for a long time. to get fresh surface exposed when the stainless
steel surface is rusted.
8.3.2.5 Inspections of paint powdering
It's a normal phenomenon that there is slight 8.4 Paint for maintenance
powdering and gloss loss of the finish paint after 8.4.1 Choice of paint brand
8-3
Machinery Co.
If the owner need purchase new paint to

repair and maintain the coating of port machinery 2） Carefully read the coating products specification
equipment, please choose the paint brand which before painting to understand environment control
same as original paint system as soon as possible. requirement of painting.
For convenience, purchasers also can choose
heavy anti-corrosion protection paints of some 3） Ordinary condition control for painting as bellow: the
famous paint brands nearby such as Hempel, temperature is no less than 5℃ the relative humidity
Sigma, IP, Jotun, ZPMC and so on. is no more than 85%, the surface temperature of
8.4.2 Choice of coating steel is more than 3℃ above the dew point.
( particular demands on coating specification).
Coatings with convenient for application,
high solid volume, fast curing or thicker film
8.5.2.3 Painting requirements
thickness is recommended for primer and
1） Carefully read coating products specification before
intermediate coat. Inorganic rich zinc primer is not
painting to mix each compounds correctly. Note the
suitable for repairing, but epoxy rich zinc primer or
pot life and forbid to use coatings exceeding the pot
high solid volume with surface tolerant coatings is
life.
proposed. The color and style of chosen top coat
should accord with original top coat.
2） Painting operations shall be performed in a proper
application method according to the recommended
8.5 Coating system inspection and instructions from coat producer integrated with
practice situation. Brush and roller are recommended
maintenance requirements for the renovation of coating system.
8.5.1 Coating system inspection requirements
3 ） The account of mixed coating should keep to
8.5.1.1 Users should arrange schedule for mechanical
principle of maximize the utilization to avoid waste
inspection and maintenance according to work amount.
and environmental pollution.
8.5.1.2 Coating system inspection and maintenance are

4） Spay is not recommended when wind speed is greater
arried out at a rainless, dry and optimum
than 7 m/s.
temperature.
8.5.2.4 Inspection and control of dry film thickness

8.5.2 Coating system maintenance requirements
8.5.2.1 Substrate treatment
1） Need to recoat several times as dry film thick is too
1 ） Surface contaminant such grease, oil should be
thin one coat when brush or roller.
removed prior to follow-up surface treatment.
2） The renovation should be according to the actual

2） Use power tool or hand tool to clean loose coatings
situation of area requiring renovation (from primer
and corrosion to minimum ST3 or SSPC-SP3. All
to top coat if primer is damaged, for example), and
surface to be renovated should be dry, and free from
make sure every renovated coat should satisfy the
contamination harmful to coating system such as
required film thickness.
grease, dust etc.
3） Make sure that the total film thick of renovated

8.5.2.2 Painting application condition control
coating system no less than 220～250 μm.
1） Painting shall be applied when weather is fine.
8-4
Machinery Co.
8.5.2.5 Appearance control requirement safety education and training is recommended.

1） Film faults must be ground feature to slope shape
with 30° to make sure a fine smoothness of 4) Learn Material Safety Data Sheet (MSDS) of
renovated film. coating before painting.
2） Grind the surface of intermediate and top coat by 5) Protective measures such as safety belt、
sandpaper (no more than 100 meshes are helmet and safety glasses etc must be taken for
recommended) is not proposed to avoid marks. applicators.
8.5.3 Special specification 6) No open flames and no cross operation in

If possible, waterborne or low VOC coatings are prefered painting operation area.
to reduce environment pollution.
8.6 Safety precautions 7) Warning sign should be erected before coating
1) Climb equipment shall be prepared before dry totally.
maintenance work is carried out.
8) Assistant materials should be recycled and
2) Scaffolds should be erected when climb uniform disposal.
equipment is absent and relative safety protection
is followed. 9) Uniform disposal of abandoned coating and
thinner, no littering and dumpling.
3) Operator should give applicator necessary
8-5
Quayside Container Crane ATTACHMENT A
Attachment A Manuals for Subcontractors (Mechanical Part)
No. Name Subcontractors

1 Reducer(Main hoist Boom hoist PIV/ZPMC
&Trolley /Gantry)
2 High speed brake Bubenzer
3 Drum brake Bubenzer
4 Pump of drum brake Bubenzer
5 Rail brake Hillmar
6 Pump of wheel brake Hillmar
7 Drum coupling Malmedie
8 High speed coupling Bubenzer
9 Head block ZPMC
10 Spreader Bromma/ZPMC
11 Cargo beam ZPMC
12 Lift ZPMC （Sheng Yang Long Chang）
13 Spreader cable reel Cavotec
14 Gantry cable reel Cavotec
15 Inside service crane ZPMC
16 Wire rope Verope
17 Air compressor Shen Jiang
18 Buffer Oleo
19 Fire extinguishing system ZPMC
20 Emergency reducer/ motor Guo Mao
21 Rope reeving reducer/ motor Guo Mao
22 Festoon Wampfler
Attachment-1
Shanghai Zhenhua Heavy Quayside Container Crane Configuration
Industries Co. LTD Special Explanation
and Maintenance Manual
Special Explanation
Ports are the hubs of land and water transportation and also the distributing centers of various cargos. Port
handling operation not only needs the combination of people and machines, but also consists of heavy and
complicated tasks which hide many potential hazards. Therefore, it is the port’s obligation to establish
relevant safety regulations and procedures to prevent accidents from happening.
The quayside cranes are also potentially hazardous. To reduce the risks of injury or danger, please always
follow the instructions in this manual when performing operation and maintenance work on the crane. Shanghai
Zhenhua Heavy Industries Co. LTD. (ZPMC) will not be liable for any damage or injury resulting from
abuse or misuse of the crane.
These quayside cranes are heavy duty, high-speed and very complicated machines with high degree of
automation, so it is impossible to foresee every potential hazard. The manufacturer, Shanghai Zhenhua Heavy
Industries Co. LTD. (ZPMC), can not envision every possible circumstance that might involve a potential hazard.
The warnings in this manual and on the cranes are, therefore, not all inclusive. When operating, inspecting, or
maintaining the cranes, each person must be safety conscious and take all necessary precautions, in
addition to following the instructions in this manual.
About Life-time Warranty
1. The lift-time warranty of quayside crane and its components will be based on the condition of proper use,
safe operation and timely maintenance by the purchaser.
2. Consumable components such as limit switch, bulb, fuse, carbon brush, oil seal, brake lining, wire rope,
lubricating oil etc. are not covered by this warranty.
3. Non-ZPMC brand or Non-ZPMC recommended parts are not covered by this warranty.
4. Emergency stop (especially full speed sudden stop) is abnormal working condition. Damages caused by
that condition shall be classified to operation accident, which is not covered by this warranty. ZPMC may
support to check and make renewing repairs.
Shanghai Zhenhua Heavy Industries Co. LTD

December, 2016
1
MAINTENANCE MANUAL
SOCIEDAD PORTUARIA REGIONAL DE CARTAGENAS.A.
TWO QUAYSIDE CONTAINER CRANES
____________________________________________________________________
SHANGHAI ZHENHUA HEAVY INDUSTRIES CO.,LTD

Address: 3261 DONGFANG ROAD, PUDONG NEW DISTRICT, SHANGHAI, CHINA
Postcode: 200125
Tel: 001-86-21-58396666
Fax: 001-86-21-58399555
Website: http://www.zpmc.com
____________________________________________________________________

ZP16-2400 SPRC Maintenance Manual (Mechanical)

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What are the main components of the quayside container crane?

What are the main components of the quayside container crane?

What safety precautions should be followed when operating the crane?

What safety precautions should be followed when operating the crane?

TWO (2) QUAYSIDE CONTAINER CRANES

SHANGHAI ZHENHUA HEAVY INDUSTRIES CO., LTD,

CHAPTER 2 CRANE MAINTENANCE INSTRUCTIONS ........................................ 2-1

CHAPTER 3 SOME IMPORTANT PARTS REPLACEMENT.................................... 3-1

CHAPTER 4 WIRE ROPE ............................................................................................ 4-1

8.3 INSPECTION PERIOD AND CONTENT OF DAILY MAINTENANCE .................................................... 8-2

Chapter 1 Brief introduction of quayside crane

This quayside container crane has twin-box trolley.

Table 1-1：Main Parameters for Quayside Container Crane

Support Beam (m) Trolley

Hoist Power (Kw) 280

Single 20′/40′/45′ & Twin-20′ Telescopic

Rail type A75 Wheel Diameter(mm) Φ800

Wheel Diameter(mm) Φ630

8 Frame Link Beam

12 Outer Boom Forestay

11 Inner Boom Forestay

15 Sea-side Sill Beam

9 Frame Link Beam

Figure 0-1: Major Drive Mechanisms Layout in Machinery Room

1.3.1 Main hoist drive

3 Motor 4 Drum Coupling 5 Reducer

6 Motor Coupling 7 Drum 8 Limit Switch Device

1.3.1.1 Main hoist reeving system

Figure 0-2: Main Hoist Rope Reeving System

1 Load Scaled Clamp Blocks on Boom Tip 2 Sheave Block on Head-block

Normal hoist limits are controlled by the absolute

As snag event occurs, the kinetic energy of the hoist

1） Trim, list and skew motions  TRIM

Figure 1-10 Spreader Left Trim  and Right Trim 

Figure 1-11 Spreader Forward List  and Backward List 

 SKEW Rotation of the spreader around a vertical axis.

8 Drum Brake 9 Bearing Seat and Limit Switch

4 Reducer 5 Drum Coupling

6 Rope Anti overlay Device 7 Drum

1.3.2.2 Boom hoist rope reeving system

Figure 1-14 Scheme of Boom Hoist Rope Reeving System

1.3.2.3 Boom hoist interlocks

1 Cam Switch 2 Over-speed Switch 3 Absolute Encoder

Limit switch Limit switch

Figure 1-16 Proximate switch for checking

1.3.3 Trolley travel system

Figure 1-19 Scheme and Photograph for Trolley Travel Drive

5 Motor Brake 6 Motor Coupling 7 Drum Coupling 8 Reducer

to the following rounte:

Figure 1-20 Trolley Rope Reeving System

1.3.3.3Trolley interlocks limits 1.3.3.4 Trolley traveling limits

1） Motor brake limit switch 1） Waterside over travel stop

4） Cab access gate

5） Trolley Encoder Reset 12） Landside over travel stop

Figure 1-22 Magnetic Inductive Limit Switches

In many cases, the wire rope length needs

The position of the cylinder is monitored by two

The function of trolley is carrying spreader and

Figure 1-26 Rope Clamp with Adjustable