Mechanical Maintenance Manual For RTG

RUBBER-TYRED GANTRY CONTAINER CRANES
FOR SPIA
ZP14-2118
Maintenance manual
(Mechanical Part)
Shanghai Zhenhua Heavy Industry Co., Ltd.

Jul ,2015
Contents
Item no. Contents Page
1 Safety 5
1.1 Warning and symbols 5
1.2 General precautions 6
1.3 General rules of conduct and safety regulations 7
1.4 Safety rules for operation 8
1.5 Safety rules for maintenance and repair 9
1.6 Conduct in case of accidents and emergency 11
2 Outline of RTG 12
2.1 General features of RTG 12
2.2 General layout of RTG 13
2.3 Principal Technical Parameters of RTG 15
2.4 Steel Structure part 16
2.4.1 General 16
2.4.2 Test procedure 16
2.4.3 Inspection 17
2.4.4 Reporting procedure 17
2.4.5 Inspection period 17
2.4.6 Typical repair procedure 18
2.4.7 Safety 19
2.4.8 Diagram of Inspection Points and Inspection Report 20
2.4.8.1 General Inspection Locations 20
2.4.8.2 Girder inspection locations 22
2.4.8.3 Fixed leg inspection locations 23
2.4.8.4 Sill beam inspection locations 24
2.4.5.5 Trolley Frame Inspection Locations 25
2.4.8.6 Equalizer Beam Inspection Locations 26
2.5 Mechanical device part 27
2.5.1 Gantry traveling mechanism 27
2.5.1.1 Composition of gantry traveling mechanism 27
2.5.1.2 Table of Gantry Traveling Particulars 28
2.5.1.3 Points for Attention in Operation 28
2.5.1.4 Inspection items and period for maintenance 28
2.5.1.5 How to replace gantry tyre 30
2.5.2 Main hoist mechanism 31
2.5.2.1 Composition of main hoist mechanism 31
2.5.2.2 Table of Main Hoist Particulars 32
2.5.2.3 Main hoist wire rope reeving and its application. 33
2.5.2.4 Points for Attention during Operation 34
2.5.2.5 Inspection Items and Periods for Maintenance 34
2.5.2.6 How to replace hoist wire rope 38
2.5.3 Hoist over travel L.S. 38
2.5.3.1 Composition of hoist over travel L.S. 38
2.5.3.2 Inspection Items and Period for Maintenance 38
2.5.4 Trolley traveling mechanism 39
2.5.4.1 Composition of trolley traveling mechanism 39
2
2.5.4.2 Table of Trolley Traversing Particulars 40
2.5.4.3 Points for Attention During Operation 40
2.5.4.4 Protection of the trolley 40
2.5.4.5 Points for Attention during trolley operation 41
2.5.4.6 How to replace trolley wheel and axle 41
2.5.5 Horizontal wheel system 44
2.5.5.1 Composition of horizontal wheel system 44
2.5.6 Trolley travel limit switch arrangement 45
2.5.6.1 Composition of trolley travel limit switch arrangement 45
2.5.7 Spreader skewing device 46
2.5.7.1 Composition of slewing device and its function 47
2.5.8 Antisway system 49
2.5.8.1 Composition of the sway - damping device 49
2.5.8.2 Arrangement and Principle 50
2.5.8.3 Sway - damping 51
2.5.9 Operator's cab 53
2.5.9.1 Composition of the Operator’s cabin 53
2.5.10 The Power Unit 55
2.5.10.1 Composition of the Power Unit 55
2.5.11 Cable Energy Chain System 57
2.5.11.1 Composition of cable energy chain system 57
2.5.11.2 Points for Attention for Maintenance 57
2.5.12 Spreader 58
2.5.13 Headblock 58
2.5.13.1 Composition of headblock 58
2.5.14 Stairs, platforms and ladders 59
2.5.14.1 Composition of stairs, platforms and ladders 59
2.5.15 Other auxiliary devices 60
2.5.15.1 Jib Crane 60
2.5.15.3 Trolley anchor device 61
2.5.15.3.1 Composition of trolley anchor device 61
2.5.15.3.2 Inspection Items and Period for Maintenance 62
2.5.15.4 Parking model for gantry 62
2.5.15.5 RTG tyre pressure monitoring system(TPMS) 62
3 Crane Inspection, Maintenance and Repair 63
3.1 Crane Travel Operation 63
3.2 Management 64
3
3.3 Maintenance and Inspection 65
3.4 Preparation of the Crane 70
3.5 Lubrication of the Crane 70
3.6 Common Troubles and Troubleshooting for the Crane 72
3.6.1 Classification of the Crane Troubles 72
3.6.1.1 Trouble in mechanical part 72
3.6.1.2 Trouble in the steel structure 73
3.6.1.3 Trouble in the Electrical Part 73
3.6.2 Causes of Common Troubles and Troubleshooting 73
Appendix
Appendix 1 Wire rope list 84
Appendix 2 Sheave list 85
Appendix 3 Tyre list 85
Appendix 4 Seal list 85
Appendix 5 Bearing list 86
Appendix 6 Roller chain list 86
Appendix 7 Brake lining list 87
Appendix 8 Lubricant grease list 87
Appendix 9 Reducer lubricant oil list 87
Appendix 10 Removing of gantry wheel 88
Appendix 11 Head block maintenance manual
4
Chapter 1 Safety
Safety is a priority either in operation or in maintenance and inspection. This
chapter informs you of the possible hazards and necessary precautions to be taken
when operating or maintaining the crane.
1.1 Warning and symbols
The following signs and symbols are used in the manual to designate instructions
of particular importance.
Special information and/or orders and prohibitions directed towards

preventing damage.
Do not enter, Authorized personnel only.
Caution
Refers to information in other parts of the Manual
Danger of falling
Keep hands clear of the moving parts.
Keep away from suspended loads
Keep hands and body clear
Stay clear
No access to the dangerous place
The maintenance personnel must be far away from the hoist motor
when crane working OR wear the ear protectors to avoid the noise
hurt
5
1.2 General precautions
This crane embodies the latest and the best in structural, electrical and mechanical
and may only be put into operation by qualified or trained staffs.
Before operating or maintaining the crane, the operation and maintenance

instructions have to be read carefully and understood by all maintenance and
repair personnel.
This machine is also built according to the latest standards of technology and
recognized safety technical rules, and is equipped with safety devices. It has been
checked for function and safety before delivery and hand-over. However, in case of
faulty operation, misuse, or use not in accordance with the instructions, dangers
and/or damages could still arise and threaten the health of the operation personnel
or third persons, the container crane or other material, and/or the efficient
operation of the crane itself.
It is always a good practice to work in a team of at least two persons in a place

where potential dangers may arise.
In addition to the operation and maintenance instructions provided herein, legal

（generally valid） and other obligatory regulations issued by the local authorities
for accident prevention and environmental protection must also be observed.
It is our admonition that working cautiously and carefully is the best protection from
accidents.
None of us has all the expertise or training needed to complete every repair that
may be required. Do not try to undertake a task on which you are lack of training or
qualifications.
IT’S ABOUT YOUR SAFETY!
The manufacturer, Shanghai Zhenhua Heavy Industries Co., Ltd. (ZPMC), has
tried his best to assemble and make available this set of instructions to provide all
necessary information for crane operation and maintenance. In case of
uncertainties, problems and additional requests, we will always be at your disposal.
Please do not hesitate to contact our local representative and/or technical
supporting staffs at the manufacturing base:
6
1.3 General rules of conduct and safety regulations
The crane may only be operated in technically healthy condition and in compliance
with the operating and maintenance instructions. Particular malfunctions that may
impair the safety must be eliminated immediately. Before each commissioning, the
crane must be checked for operational safety!
Uncompleted or illegible operation and maintenance must be replaced

immediately.
Protection and safety devices (covers, safety barriers, etc.) must not be removed
while operating the unit. The crane must not be operated without safety devices at
any time.
Appoint personnel solely responsible for the crane operation and maintenance
respectively. Also, do not permit unauthorized personnel to operate the crane.
The operating and maintenance staff has to be checked by the employer

responsible for the operation. The person responsible for the operation is obliged
to operate the crane only in proper condition and to instruct the operating and
service staff to wear protective clothing, etc. whenever necessary or required by
the regulations.
If there are any alterations concerning the safety of the machine or changes in the
operational behavior, the machine has to be set to a standstill and the fault has to
be reported to the relevant authority or person. Damages affecting the safety or
malfunctions at the crane have to be eliminated immediately.
Arbitrary constructive modifications and the alteration of parameters beyond the

operating and maintenance instructions are not permitted for the sake of safety
technical.
IMPORTANT SAFETY PRACTICE!
The following safety rules must be observed strictly in practice:
(1) Verify that there is no danger to other related personnel before operating the
machine.
(2) Do not touch the rotating parts or the moving parts of the machine during
operation.
(3) Do not perform inspection and adjustment of the machine during operation.
(4) Do not touch the live parts inside the control cabinets or terminal boxes.
(5) Do not lubricate the components of the machine during operation.
(6) Immediately press the emergency stop pushbutton to stop the machine when
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an accident has occurred or is likely to occur.
(7) Always keep the machine and it’s surroundings clean. Especially Keep the
passageways at the elevated place clean so that personnel can walk safely.
(8) Warn all the service personnel of an unsafe intended action that may endanger
them.
(9) Report any injury and make sure the wounded person can receive fast medical
treatment.
1.4 Safety rules for operation
Pre-service Precautions:
(1) Before starting work at the crane, all persons have to be instructed in theoretic
and practical use of emergency measures in case of an accident, the use of the
emergency exits, and the use of rescue aids (fire extinguishers).
(2) Unauthorized persons should not enter the crane.
(3) All safety devices and facilities with protection functions must always be
connected and operable. They must not be rendered ineffectively or used
improperly.
(4) The factory setting of the components must not be changed.
(5) Observe the inspection procedure stated in this manual for the inspection of
each component.
(6) Check for obstructions on the gantry runways.
(7) Check that lubrication for every mechanical part is sufficient.
(8) Check that every operation joystick and operation switch is in normal
position.
(9) Check that power supply voltage is normal.
(10) A trial run without load should be done first and the running with load can be
started only after it is confirmed that various safety devices and limit switches
are activated normally.
Precautions during service:
(1) Do not step into an area below the cargo lifted when the crane is operating. It
may result in a critical accident.
(2) The lifting load and the reach during the loading or unloading operation must be
within the limit values defined by the specifications of the crane. Excess reach
8
or excess load may result in a critical accident such as a fall-down, a break-
down or a damage of the crane.
(3) Immediately stop operating the crane when an abnormal sound or vibration
arises. Inform the responsible personnel immediately to eliminate the
malfunctions or conduct maintenance.
(4) Do not leave the crane with any openings into which a person could step or
tools and objects could fall. And do not leave lubricants, paints, or other
materials uncovered or un-attended.
(5) Always operate the crane smoothly to prevent the shock of start-up or
stoppage. Avoid operations such as abrupt loading or unloading at full speed
with excess load or unnecessary repetition of start-up or stoppage.
(6) When the crane encounters typhoon, the gantry tie down devices must be
applied and fastened properly.
DANGER ZONE MUST BE BLOCKED BY SUITABLE MEASURES.

HAZARD AREAS MUST BE INDICATED PERMANENTLY BY CLEAR
INDICATIONS, SUCH AS COLORED SIGNS OR WARNING SIGNS.
Cautions after service:
(1) Park the Crane at the assigned location.

(2) Park the trolley at the stowed location, i.e., anchoring location.
(3) Return all the operation joysticks and switches in the cab to neutral position
and specified position.
(4) Check the rubber-tyred wheels.
(5) If the Crane is not expected to be in use for a long period or a storm is
forecast, the Crane should be secured with anti-storm tie downs.
(6) Repair defects found during operation and confirm that all lubricants are
correct for the next operation.
(7) Lock the doors of the operator's cabin, electrical room and engine room to
prevent unauthorized entry.
1.5 Safety rules for maintenance and repair
The maintenance work is different from the ordinary operations. When the crane is
under maintenance, some of its parts may be disassembled or unstable, thus
special attentions should be paid to.
BEFORE COMMENCEMENT OF SERVICE WORK THE CONTAINER
CRANE HAS TO BE MADE FREE OF LOAD, SET TO MAINTENANCE
POSITION AND SWITCHED OFF, IF NO OTHER NOTE IS GIVEN.
Observe the following safety rules when conducting maintenance or inspection

work on the crane:
9
(1) Personnel unauthorized by the person responsible for the crane should not
perform maintenance or inspection work.
(2) Do not perform maintenance or inspection work when the crane is operating.
(3) Before conducting maintenance or inspection work, shut down the engine
generator set cut off the main power supply and all the power resources; then
verify if the crane is stopped completely.
(4) Before conducting maintenance or inspection work, warn all the related workers
of the work and prohibit entry of those unauthorized workers into the
maintenance and inspection areas.
(5) The crane should be in maintenance mode for such a task.
(6) Secure the repair area by closing a wider area. During the maintenance of the
crane, be sure to close all the openings on the platforms or other places, or
protect them with fences.
(7) When inspecting one of the cranes on the same gantry runway, attach the
mechanical stoppers or station a person to prevent collision of the cranes.
(8) Never fail to close the door to the walkways and the chains at the gate of the
walkways.
(9) When removing bolts, pins, wire ropes, and cables, warn workers other than the
service personnel of the danger of attached parts falling.
(10) If hands will be on the rope for inspection, they must be away from the pinch
point.
(11) The maintenance persons should pay more attention to the moving/rotating
parts.
(12) Do not use the machine parts as climbing aids.
(13) Reinstall and test safety devices (which have been disassembled during the
assembly or test and repair work) immediately after the end of the maintenance
and the repair work.
(14) Correctly tighten the screw joints that were loosened during the test and the
maintenance work.
(15) Replace the fastening elements and seals (e.g. self-securing nuts, washers,
split pins, O-rings and seals) which cannot be used again.
(16) After the maintenance/repair work, update the fault log and the maintenance
check list.
(17) Do test running and functional check of the components and safety devices
10
before starting the operation and service again.
1.6 Conduct in case of accidents and emergency
(1) In the case of an accident with injury to persons, damages to devices or other
materials, immediately inform the supervisor after providing the injured with first
aid. For well-directed rescue efforts, clearly give the degree of severity of the
injury to persons and the damage to property.
(2) In case of disasters (e.g. fire), all persons must leave the crane using the
indicated emergency exits and/or other facilities.
(3) Rescue actions may only be carried out by instructed operating and rescue
personnel. Use the intended protective equipment.
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Chapter 2 Outline of RTG
2.1 General features of RTG Cranes

ZPMC have been supplied over thousands of RTG Cranes for the worldwide
users.
These RTG cranes are constructed from various components groups.
The RTG Crane is supported on 8 rubber-tyred wheels and powered with
a diesel-alternator set which supplies power to every movement drive.
The crane is equipped with a telescopic spreader which is able to handle
20', 40' , 45', 48' and 53' standard containers (with corner fittings at 20 or
40’ position). The Crane is provided with a sway damping device to reduce
spreader sway and increase productivity. The Crane also has a spreader
slewing device for easier spotting of the container. A 90-degree wheel
turning system together with a 360 crane rotating system allows ease of
movement.
The typical dimensions of the Crane is able to pass across 6 rows of

containers plus one truck way (6+1 lane) and to pass over five containers 9'
6" high with one 9’6” container lifted under the spreader(1 over 6).
The gantry frame of the Crane is of box-section welded construction. The

trolley rail is blots on the upper girder. The equalizer beam is connected to
the sill beam through a hinged pin which is fixed with a keeper board. Each
equalizer beam has two bogie trucks and two wheels.
Constant power control is used for the main hoist; hoisting speed is
automatically adjusted depending on the load being lifted. The main hoist
has an overload protection device and over-speed protection to ensure safe
and efficient operation of the Crane
An operator's cab is located under the trolley frame, and from there the
operator may operate the Crane. The trolley is driving by one set of motor.
The operator should thoroughly read these instructions and should be

specially trained in operation for a period. The container slots and lanes on
the stack-yard should be designated with white lines. The electrical safety
protection devices on the Crane should be adjusted properly.
For safety and protection the Crane has overload protection, diesel
engine over-speed protection, high water temperature and low oil
(lubrication) pressure signaling, anemometer, anti-collision devices for
gantry traveling located on four corners, emergency stop buttons, spreader
load indicator, limit switches for every movement and signal indicators, etc.
12
The Crane has lighting and signaling equipment for operation at night.
The gantry traveling is provided with alarms. For intercommunication
between the operator and the dock the Crane has telephones, a public
address system and radio speakerphone.
2.2 General layout of crane
Figure 2.2-1 Crane general layout
As shown in Figure 2.2-1, the main composition of crane is as follow:

1- Gantry traveling mechanism
2- Tyre Pressure Detector
3- Gantry frame
4- Stairs, platforms and ladders
5- Name plate arrangement
6- Trolley arrangement
7- Electric house
8- Energy chain Mechanism
9- Power set
10- Limit switch ass.
11-Jib Crane
12- GPS and RCMS
13-Hydraulic Station
14-Headblock
15- Spreader
13
Figure 2.2-2 Trolley layout
As shown in Figure 2-2.2, the main composition of crane is as follow:
1- Trolley travel mechanism

2- Trolley Frame
3- Wire rope reeving system.
4- Anti-sway sys.
5- Walkways and Platforms
6- Operator’s Cabin
7- Over height limit
8- Hoist Mechanism
9- Trolley anchor device
10-Side Roller
11-Centralized lubricate
12- Reflector
13- Spreader cable fixer
14- Trolley cable fixer
15- Connect Box
14
2.3 Principal Technical Parameters of RTG
Item Value Unit Remark

Rated lifting capacity 41 T
Lifting height 21 m
Hoisting full load 25 m/min
Speed
no load 60 m/min
Working Gantry full load 30 m/min
speed traveling
speed no load 90 m/min
Trolley traveling speed 70 m/min
Span 23.47 m
Wheel Base 7.9 m
Total number of driving wheels 4 pieces
Spreader horizontal 5 degree
Spreader slewing
Spreader Trimming 2.5 degree
Model QSX15-G7 Cummins
Diesel Power 620 BHP Primer
engine
Speed of rotation 1800 rpm
Model HCI 634 – K2 Stanford
Alternator Power 823 KVA
Speed of rotation 1800 rpm
Number of containers stacked by the 6 container
crane s
Number of containers the crane may 6 container
pass over s
15
2.4 Steel Structure part
2.4.1 General
The steel structure part consists of developing inspection procedures and

determining inspect intervals based on rational analysis using the principles of
fracture mechanics.
Welded steel structures always contain undetectable cracks. The cracks
grow when subjected to fluctuating stresses beyond a very small value. There
are no crane specifications used today that have stresses at such a low level
that fatigue crack growth will not occur on a random basis.
Periodic inspection is required to detect fatigue to avoid serious failure in the
crane structure. The inspection method shall be selected to detect fatigue
cracks. Only the critical locations on all members are those locations where
fatigue cracks, if any, would be expected to initiate. The inspected region shall
extend a reasonable distance beyond the critical point. The inspection for
fatigue cracks shall always include Visual Testing (VT) and may incorporate
non-destructive testing methods, i.e., Magnetic Particle Testing (MT) or
Ultrasonic Testing (UT), MT shall be used at the critical locations of fillet welds
and both UT shall be used at the critical locations of butt welds.
2.4.2 Test procedure

1. Visual Testing
The surface should be free of dirt and grease. Cracked paint requires further
inspection by MT or UT.
2. Magnetic Particle Testing
The test surface must be free of loose rust and moisture. If required, clean
painted surfaces with power tools by grinding, or needle scaling. An
electromagnetic device, such as a yoke, may be used to a magnetic field.
3. Ultrasonic Testing
Testing should be done in accordance with approved method and the
requirements shown in "INSPECTION"
16
2.4.3 Inspection
1. All bolted and welded joints shall be visually inspected (VT).

2. Visual inspection shall be performed by a certified AWS QC-1 inspector.
3 NDT inspection shall be done by qualified person.
4. NDT shall comply with the requirements of all of AWS D1.1-96, including Section
5. "Inspection", and all provisions applicable to cyclically loaded structures.
6. Required inspection is shown on the attached sketches for the critical details.
7. Where MT or UT inspection is indicated on one side only, the inspector shall
inspect the weld form both sides unless otherwise noted.
8. Inspection of bolts shall comply with AISC Specification for Structural Joints Using
(CHINA) GB1228-94 10.9 GRADE bolts (equivalent to ASTM A490 Bolts, latest
edition).
2.4.4 Reporting procedure

All indications of defects should be shown on the table attached with
sketches the weld detail. The following information should accompany the sketch:
1. Crane identification.
2. The side and extent of defect.
3. Weather defect is in the toe of the weld, propagating into the base metal, etc.
4. Defect location: right-hand side, left-hand side, which box section, crane leg
number, waterside, landside, distance in inches to nearest station, etc.
5. Method of testing: VT, MT, and UT.
6. Inspector's comments and signature
2.4.5 Inspection period

1. Initial inspection: Visual inspection six months after crane acceptance.
2. Complete inspection: Visual and NDT as shown in manual three months before
the end of the warranty period. Inspect six year points and others as designated
by the port.
17
3. Maintenance inspection as shown in manual.
2.4.6 Typical repair procedure

1.Work shall be conform to the requirements for Structural Steel Buildings,
Allowable Stress Design, ninth or latest edition, including current supplements,
and AWS Structural Welding Code, D1.1-96,or latest edition, including all
provisions applicable to cyclically loaded structures and Section 8, "Strengthening
and Repairing Existing Structures".
2. All temporary attachments shall be removed after completion of work.
Removed weld area shall be ground smooth and a prime paint coat applied to the
surface.
3. All repaired joints exposed to weather shall be seal welded.
4. Welders and welding operators shall have current AWS certificates for the
materials and processes being used. The Contractor shall maintain current files of
these certificates and shall provide the certificate to the Port at the Port's request.
5. Weld procedures shall be qualified in accordance with AWS D1.1-96 or latest
edition.
6. The Port may perform NDT testing of the Contractor's work. The Contractor
shall allow unrestricted access for such testing to the Port or the Port's
representative.
7. The structural drawings identify Fracture Critical Members (FCMs)
8. Electrodes shall be in accordance with Table 3.1 of AWS
D1.1-96, or latest edition, except E60XX rods shall not be used. FCMs shall be
welded with electrodes with an AWS toughness rating of at least 20 ft-lbs at -
20%DF. For SMAW electrodes, see Table 4 of AWS A5.1-96, or latest edition, for
toughness rating. For other welding processes, see applicable AWS standards.
9. All areas where paint has been removed, or damaged, shall be restored to its
original condition in accordance with the original crane specifications.
10. Re-tightening of bolts after inspection shall be according to relative standard.
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2.4.7 Safety
At all times the Contractor shall be solely and completely responsible for
conditions of the job site, including safety of persons and property, and for all
necessary independent engineering reviews of these conditions.
Stairs, ladders, railing, or walkways furnished, or modified, by the Contractor shall
conform to OCCUPATIONAL SAFETY GENERAL REGULATION requirements.
ALL PRECEPTS OUTLINED IN THE “Chapter 1 Safety” APPLY TO THIS

TEST, INSPECTION AND REPAIR.
19
2.4.8 Diagram of Inspection Points and Inspection Report
2.4.8.1 General Inspection Locations
20
21
2.4.8.2 Girder inspection locations
22
2.4.8.3 Fixed leg inspection locations
23
2.4.8.4 Sill beam inspection locations
24
2.4.8.5 Trolley Frame Inspection Locations
25
2.4.8.6 Equalizer Beam Inspection Locations
26
2.5 Mechanical device part
2.5.1 Gantry traveling mechanism
2.5.1.1 Composition of gantry traveling mechanism
Figure 2.5.1-1 RTG Gantry traveling mechanism

Please see figure 2.5.1.1-1 for composition of gantry traveling mechanism. The
gantry traveling has 8 rubber inflated tyres; four of the tyres are drive ones and
laid on each corner of the crane (two tyres at each corner). The other four wheels
are idle. Each corner of gantry is equipped with hydraulic cylinders for steering
and locking. Through a lever system each tyre can be rotated about its center by
90 0. This process must be performed under non-operational conditions and at
the assigned location. Each tyre can also be rotated to an intermediate position
to allow the RTG rotate around its central axis. The bogie frame rotating support
is skewing bearing which are lubricated with grease. The tyres are of 21.00-25,
40ply, tubeless. The tyres have external safe guards.
27
The traveling mechanism has 4 horizontal vertical-flanged motors with integrated
brakes, which drive 4 gantry wheels. In addition, the gantry traveling is provided
with an anti - collision device, telephone by which one can communicate with the
operator in the cab, acoustic and visual alarm for traveling, etc.
2.5.1.2 Table of Gantry Traveling Particulars
Description Value Unit Remarks
Gantry travel with empty 90 m / min

speed spreader
with rated load 30 m / min
Motor 1LP4 188 Siemens

Power 30 kw
D.C. motor Revolutions 1650 rpm
Qty. 4 sets
Model FVS395.30.D3B-00 ZPMC
Reducer Reduction ratio 30.112
Qty. 4 sets
Brake Model KFB40 Built-on the motor
Qty. 4 sets
Model 21.00-25 40 PR ZPMC
Rubber tyres Effective diameter Φ1573 mm
Inflation pressure 10 kg/cm2
Qty (drive / total) 4 /8 pc
2.5.1.3 Points for Attention in Operation
After a long term of non - operation or after disassembly and re - assembly the
Crane shall first be run without load allowing the reducers, bearings, etc. to be
lubricated fully and their condition carefully observed. Then operation with a
load can be started.
2.5.1.4 Inspection items and period for maintenance
(1) Oil (grease) supply: During oil (grease) replacement the old oil (grease) shall
be discharged thoroughly. Generally speaking the lubricant shall not be mixed,
especially the grease. Mixed grease may result in blockage and bearing
damage.
(2) All parts and components
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Loosening of securing bolts
Attention shall frequently be paid to loosening of the bolts, particularly after
the first week of Crane running and then once per month check all the bolts
and re-tighten them. Special attention shall be paid to those bolts which
contribute to fastening but are easily neglected.
Period : routine and once per month
Check whether lubrication is correct. Lubricate in accordance with lubrication
schedule.
Period : routine
(3)Motors
Check temperature rise for any abnormal condition
Check for any abnormal heating in the bearings.
Check for any abnormal noise in the motor.
Axial play of the motor is generally controlled within 3mm and the maximum
shall not exceed 5mm.
Period: routine
(4)Drive and driven axle

Check whether oil level is adequate.
Check for oil leakage.
Check for abnormal temperature rise. If the casing temperature is higher than
the ambient temperature by more than 40C, the inner part shall be inspected.
Check for abnormal noise in the internal part and disassemble and inspect if
there is any.
Check for loosening of connection bolts.
Period : all above are routine.
For detail, please refer to the “Instructions of reducers model
82.2386.3a, 82.2387.3a”.
(5) Tyre
7.4.5.1 Check that every tyre is inflated sufficiently. The right tyre pressure
shall be 1000kPa (10.0 kg/cm2).
Period : routine
(6) Slew bearing

Bolt Inspection: When the slewing bearing works continuously for about 100
hours after installation, the installation bolts must be inspected fully for their
preload. The preload must meet the requirements. And the installation bolts
must be reinspected after continuously work for 500 hours.
Greasing: The raceway of the slewing bearing must be regreased at regular
intervals. Generally, if the rolling elements of the slewing bearing are sphere
29
shaped, the raceway must be regreased after working for 100 hours; For high
temperature and dusty working environment, regreasing interval must be shorter.
And also if the bearing works continuously for a long period, it must be
regreased. The slewing bearing must be 100% greased at each time.
Bolt Inspection: When the slewing bearing works continuously for about 100
hours after installation, the installation bolts must be inspected fully for their
preload. The preload must meet the requirements. And the installation bolts must
be reinspected after continuously work for 500 hours.
(7) Turning hydraulic cylinder

For detail, please refer to the hydraulic manual.
2.5.1.5 How to replace gantry tyre
For details, please refer to Annex Ten

REPAIR.
DANGER WITH JACKING DEVICE! MAKE SURE THAT THE HYDRAULIC

JACK IS NOT LEAKING AND IS NOT LOWERING PRESSURE !
30
2.5.2 Main hoist mechanism
2.5.2.1 Composition of main hoist mechanism
Figure 2.5.2-1 Main hoist mechanism
Please see figure 2.5.2-1 for composition of main hoist mechanism. The drive
mechanism of the main hoist is installed at the right part of the trolley and consists
of a motor, a high speed flexible coupling, a gear reducer, a low speed barrel type
gear coupling between reducer and drum, two brakes and tachometer, over－
speed protection, limit protection , etc. The motor drives the reducer through a
flexible coupling which drives the drum to wind up or pay out the 4 sets of wire
ropes which in turn lift or lower the spreader. One of the disc brake is fitted on the
motor coupling and the second on the other side of the gear box. The brake disc
should be replaced if it is worn to the value equal to 30% of its thickness. The
braking torque of each disc brake is greater than 1.5 times the motor torque.
The main hoist drum is made of plate steel with a nominal diameter of 1200mm.
The drum is provided with four (4) sets of group of grooves. One end of the drum is
31
connected to the reducer through barrel type coupling and the other end is
supported on the stub-through bearing which is seated on the trolley frame.
The main hoist is provided also with over-speed protection device which are located
at the rear part of the motor. The over-speed protection is activated when the motor
speed reaches 115% of its rated speed to stop main hoist movement. Limit
protection is fitted at the other end of the drum. This device provides the following
protection:
1) Stopping at upper lift end;
2) Stopping at lift lower end;
3) Slowing down before reaching upper and lower lift ends;
4) Stopping at lift upper extreme limit end.
2.5.2.2 Table of Main Hoist Particulars

Description Value Unite Remarks
Number of wire ropes 4 pcs
coming from the drum
Multiple of rope reeving of sheave block 2
Lifting capacity (under spreader) 41 Te
Hoisting with full load 25 m / min
speed With empty spreader 60 m / min
Nominal diameter 1200 mm
Number of groups of grooves 4 groups
on the wire rope drum
The drum Number of wraps of rope 1 wraps
for fixing
Capacity of the drum 60.2 m
(one group of grooves)
Model 1PQ83556 Siemens
Power 200 KW
Motor Revolutions 730 / 1753 rpm
Qty. 1 set
Model FH1260.55.C1A-00 ZPMC

Power 200 KW
Qty. 1 set
Model SB28-630x30- BUBENZER
ED121/6
Model of thruster ED121/6 BUBENZER
Brake Rated Braking torque 4100 Nm (each brake)
Qty. 2 sets
Model IWRC 6xFi(29)--Ø25 Bridon
32
right hand
Diameter Ø25 mm
Wire rope Length （including the safety 74.8 m from drum bearing
length） pedestal side
70.3 m
70.7 m
74.4 m
2.5.2.3 Main hoist wire rope reeving and its application.

There are four (4) main hoist wire ropes (from the drum bearing pedestal
side) of 74.8m, 70.3m, 70.7m and 74.4m in length (including the tolerance),
and they are IWRC 6xFi(29) -Ф25 (bridon) type. The four (4) ends of these
ropes are fixed on the drum through 3 clamps for each. The clamps are
located 15 0 apart from each other and each clamp secures one wraps of the
rope. The clamp bolts are of M24. Two wire ropes come out from the drum
and go downward to the headblock’s sheaves; one of the ropes then returns
to the lower end of the trolley I shape beam; the other rope goes through
one slewing sheave block and then is fixed to the slewing device side of
the trolley. The other two ropes come out from the drum and pass across
the sheave blocks located on the trolley and then go downward to the
corresponding sheaves on the headblock; then one of them returns to the
end of I shape beam of the trolley frame, and the other rope passes across
the slewing sheave and then is fixed to the other end of slewing device.
During reeving of the wire ropes the four sets of them shall be tensioned
equally. If uneven tension between them is found, the end securing clamps
may be loosened and tightened up or release the appropriate rope(s), or
simply adjust the slewing mechanism to vary the rope lengths accordingly to
make tensions between the ropes even. After the first period of Crane
running, the ropes must be re-adjusted depending on their stretch. In normal
operation uneven tension between the four sets of wire ropes shall be
corrected immediately once it is found.
Attention shall frequently be paid to the fastening condition of the wire rope
clamps and tighten them if loosened. Frequently check bolts of the clamps
and replace them immediately if thread damage, cracks, etc. are found. The
ropes shall not be twisted or knotted during reeving.
The wire ropes shall frequently be checked during application and shall be
replaced if wires damaged account for 1/10 the wire in the whole strand or if
the diameter of the wire rope is reduced by 7% of its nominal size due to
surface wear. Pay attention to inspection for the rope jumping out of the
sheave groove and if there is any interference of the wire rope with other
mechanical or structural parts.
33
2.5.2.4 Points for Attention during Operation
After a long term of non-operation of the Crane or after disassembly and re-
assembly, the Crane shall be run first without load enabling the reducers,
bearings, etc. to be lubricated sufficiently and operation with load can be
started only it is confirmed that the running condition is normal.
2.5.2.5 Inspection Items and Periods for Maintenance

(1) Oil (grease) supply
When the oil (grease) is to be replaced the old oil (grease) must be drained
thoroughly. Generally the lubrication oil (grease) shall not be mixed,
particularly the grease. Mixed grease may cause blockage that results in
bearing damage.
(2)All parts and components
Check for loosening of fastening bolts
Frequently check for bolt loosening, especially one week after the Crane’s
first running and then once per month all the bolts shall be inspected and re-
tightened. Special attention should be paid to those bolts which contribute
to securing but are easily neglected .
Maintenance period: routine and once per month
Check that lubrication is correct.
Lubrication should be done in accordance with Lubrication Schedule.
Period: routine
(3) Electrical Motors
Check temperature rise and overheating.
Check whether the bearing is abnormally heated.
Check for abnormal noise inside the motor.
Check the motor axial play which is generally controlled within 3 mm and
max .5mm.
Maintenance period: routine
(4) Gear reducer
Check that the oil is adequate by using the oil level indicator.
Check for oil leakage.
Is there any abnormal temperature rise? If the temperature is more than
50degrees above the ambient temperature, the internal portion should be
inspected.
Check for abnormal noise inside the reducer and disassemble and inspect if
any abnormal noise occurs.
Check connection bolts fastening
Maintenance period: all are routine
For detail, please refer to the “Instructions of the reducer model
FH1260.55.C1A-00”
(5)Coupling
Check whether the bolts are loosened. Period: routine
34
Check eccentricity and end run-out of the two halves of coupling. Normally
check once per year.
Insure normal lubrication for the drum coupling.
Period: routine
For detail, please refer to the “MAMEDIE series hoist drum coupling
manual” .
(4) Drum
Check for loosening of the securing bolts.
Period: routine
Check whether wear of the rope grooves exceeds limit value which is
generally 20% wire rope diameter.
Period: once per month
(5)Anti - friction bearing (rolling bearing)
Temperature rise shall not exceed 50C (in comparison with ambient
temperature).
Check for abnormal noise.
Period: routine
Check for loosening of connection bolts.
Period: routine
(6) Encoder
Check whether the transmission is in good condition.
(7)Brake disc
Check the disc surface for uneveness (convex-concave) which should not
exceed 0.3mm, and correct if necessary.
Period : once a month
Check whether wear exceeds limit and replace the disc when wear exceeds
30% of thickness.
Period : once per month
Check whether temperature rise is abnormal on surface.
Period : routine
Check whether the disc surface is damaged or contaminated with oil
(grease).
Period : routine
Check for fine cracks.
Period : routine
(8) Brake
Check that the brake action is maneuverable
Check wear of the brake. The limit value is 3mm and replace if the limit is
exceeded.
Clearance at the brake shoe shall be kept to 0.5 -1.5mm.
Every pivot pin shall be frequently greased. Frequently check wear of the
pin and matched fore.
Period: routine
5.4.11 Check the pulse signal transmitter for height indication
35
5.4.11.1 Check that gearing is in good condition
5.4.11.2 Check that pulse signal transmission is correct.
Period: routine
For detail, please refer the brake manual from Bubenzer.
2.5.2.6 How to replace hoist wire rope

REPAIR.
Figure 2.5.2.6-1 Hoist wire rope reeving
Hoist wire rope replacement shall be carried out in no-wind weather condition.
Consider the following basic steps to accomplish the replacement:
1. Before replacement, preparation work shall be done such as various

replacement parts (new wire rope etc.) and required tools put at hand.
2. The working area shall be clear and enclosed with warning line and caution.
36
3. First, cut the new ropes as which length and quantity according to the drawing’s
requirement (see figure 2.5.2.6-1) and then complete the pressed rope connector.
Otherwise, prepare some jute ropes which diameter about 20mm and wires for
binding.
4. To lower the spreader onto the ground and make it steady, then loosening the
wire ropes slowly until they lay on the headblock steadily and loosening continued
until that wire ropes remained on the drum approach the fixed bolt. When the wire
ropes loosened completely, shut down the diesel generator set.
5. Binding the 4 old wire ropes which wind on the drum with jute ropes, then remove
the fixed bolt and take off the wire ropes which remained on the drum carefully.
Then pulling the jute rope let the old wire rope falling down to the ground by gravity.
7. Take the 4 old wire ropes connector which connected to the lever of the skewing
system binding with jute ropes. Take out the old connector, lower the rope to the
ground.
8. Using jute ropes reeve through the sheaves according to the rope reeving system
drawing and binding with the 4 end of the new wire ropes, pulling them up to the
trolley and winding the wire ropes onto the drum by 3 circles, then fastening that
ropes with bolts primary.
9. Other 4 wire rope connectors binding with jute ropes and pulling them up to the
trolley in place, then connect with the level of the skewing system.
10. After wire ropes replacement are completed, start the diesel generator set,
switch on the power source, raise the spreader above the ground about 300mm.
Observe the wire ropes slack and the headblock deflection in level. Adjust the ropes
slack by loosen the bolt which fixed the ropes ends on the drum, and tension the
slack rope, then fasten the bolt and cut off the unwanted part of the rope.
DANGER! THE PERSON ON THE GROUND SHALL PREVENT FROM

HITTING BY WIRE ROPE FALLING DOWN.
DANGER! WHEN THE HOISTING/LOWERING IS RUNNING, KEEP AWAY

FROM THE HOIST MECHANISM, DO NOT TOUCH ANY ROTATING
COMPONENTS. ALL THE PERSON ON THE TROLLEY SHALL BE
PROVIDED WITH SAFE BELT.
2.5.3 Hoist over travel L.S.
37
2.5.3.1 Composition of hoist over travel L.S.
On the anti-sway platform, there is a gravity type hoist over travel L.S. It consist of
L.S., wire rope, guide pipe, strike rod etc. For emergency, if the hoist motion failed
to stop at rated hoist height, the strike rod will touch the top surface of headblock,
the over travel L.S. will act immediately, the hoist motion will be stopped.
Figure 2.5.3-1 Hoist over travel L.S.
2.5.3.2 Inspection Items and Period for Maintenance

Check bolts for loosening
Frequently check bolts for loosening, particularly after the first week of running and
then once per month check all the bolts and re - tighten them. Pay special
attention to those securing bolts that may easily be neglected.
Period: routine
2.5.4 Trolley traveling mechanism
38
2.5.4.1 Composition of trolley traveling mechanism
Figure 2.5.4-1 Trolley traveling mechanism
Please see figure 2.5.4-1 for composition of trolley traveling mechanism. The
trolley drive mechanism includes two (2) electric motors which drive reducers
through couplings. The reducers in turn drive the wheels through universal shafts
to propel the trolley along the rail. The wheel system consists of wheels, wheel
shafts supports, bearings, etc.
2.5.4.2 Table of Trolley Traversing Particulars

Description Value Unite Remarks
Traversing Speed 70 m / min
Model 1LG4_207- 4 Siemens
Power 30 KW
Motor Revolutions 1800 rpm
Qty. 1 sets
Model FH495.40.A2A-00- M ZPMC
（M type ）
Input Power 30 KW
Qty. 1 set
Model SB8.11-355x20-ED23/5－L BUBENZER
39
Brake Model of thruster ED 23/5 BUBENZER
Rated Braking 300 Nm
torque
Qty. 1 sets
Wheels Diameter 500 mm
Qty. 4 pc
Trolley Rail P43
2.5.4.3 Points for Attention During Operation
To ensure normal operation of the trolley and reduce shock, careful inspection is
needed .
(1)Check that the noise in the reducer is normal, that the bearing is not overheated,
and that the oil level is correct . If any of these problems appear, the Crane
should be stopped immediately and the problem corrected.
(2) Periodically check that the attachment of the wheel to its shaft is firm and if the
end fastening bolts are loosened. They should be tightened regularly.
(3) Periodically check for wear on the trolley wheels since a difference in diameters
between wheels affects their synchronization. Wheels shall be replaced if their
wear reaches certain limit that may affect smoothness of traversing. If the
wheels are found to be worn rapidly, the cause must be found and removed.
The diameters of the four wheels shall be within the same tolerance.
2.5.4.4 Protection of the trolley

Both (forward and backward) traverse end protection.
Both (forward and backward) end extreme limit protection.
Both (forward and backward) end slow down.
Trolley anchoring limit protection.
Cabin platform gate open protection
Polyurethane buffers are fitted at both ends of the girders to protect the trolley in
case of failure of all the end protection and end extreme limit protection.
2.5.4.5 Points for Attention during trolley operation
40
(1) In case of abnormal noise during traversing it is necessary to check if the
horizontal wheels are loosened or dropped, etc. After the above causes are
removed, if abnormal noise still occurs the reason may be binding the rail or
friction between the rail and rail support beam. In this case add a little oil
(grease) where the noise occurs.
(2)Each time after operation has been completed the operator shall position the
trolley at the parking location and anchor it using the anchoring device to prevent
the trolley from moving along the rail due to wind gust or other causes. Each
time before operation the anchor must be released.
(3) Normally the trolley forward and backward end extreme limits are not activated,
and if they are activated the causes shall be found out and removed. They shall
be periodically checked and maintained.
(4) Pay special attention to the nuts on the screw lever on the bumper support and
check them once per shift and tighten them if loosened.
(5)Check carefully the operator's cab suspension support, operation condition of
the wheels and the rail track for abnormal matter and the connection welds and
bolts on the cab support.
(6) Periodically grease every lubrication point to ensure normal lubrication.
(7)For motors, reducers, couplings, etc. maintenance shall be the same as that for
the main hoist.
For reducer detail, please refer to” Instructions of reducer model
FH495.40.A2A-00- M”.
For brake detail, please refer to the manual of Bubenzer.
2.5.4.6 How to replace trolley wheel and axle

REPAIR.
Trolley wheel and axle replacement shall be carried out in no-wind weather condition.
Totally four trolley wheels, located at each corner of the trolley.
Consider the following basic steps to accomplish the replacement:
41
1. Before replacement, preparation work shall be done such as various replacement
parts(new wheel and axle etc.) and required tools(hydraulic jacks, electrical
impact wrench, mobile crane etc. ) put at hand.
2. The working area shall be clear and enclosed with warning line and caution.
3.The crane is at non working condition and stay at a level ground, the trolley shall be
parked and anchored at the middle of the girder，lower the spreader and headblock
onto the ground.
4. If the replaced trolley wheel is at horizontal wheel side, dismantle the horizontal
wheel and its bracket first; If the replaced trolley wheel is at non horizontal wheel
side, dismantle the plate in front of the trolley (at the end of the trolley frame).
5. The drive end of the trolley wheel is connected with universal shaft through bolts
and shaft sleeve, loosing the connecting bolt and dismantle the shaft sleeve (see
figure 2.5.4.6-1).
Figure 2.5.4.6-1 Trolley wheel connect with universal shaft

6. Dismantle the connecting bolt between the wheel assembly and trolley frame as
show in figure 2.5.4.6-2, totally 12 no. of M20 bolts.
7. Put one hydraulic jack(rated at 16T) under the jack up pad as show in
figure2.5.4.6-2(it is better to put a hardwood pad under the hydraulic jack to
decentralize the pressure on the girder), jacking up about 170mm, and then rolling
the wheel assembly along the trolley rail until come out of the trolley frame.
42
Figure 2.5.4.6-2 Trolley wheel jack up
DANGER WITH JACKING DEVICE! MAKE SURE THAT THE HYDRAULIC

JACK IS NOT LEAKING AND IS NOT LOWERING PRESSURE !
DANGER! HOLD THE WHEEL ASSEMBLY CAREFULLY, PREVENT FROM

FALLING DOWN TO THE GROUND.
8. Use mobile crane to lower the wheel assembly down to the ground. The total
weight of wheel assembly is about 500kg.
9. Dismantle the wheel assembly, replace the old wheel and axle with new one,
reassembly the wheel assembly as per figure 2.5.4.6-3
Figure 2.5.4.6-3 Trolley wheel assembly

10. Use mobile crane to hoist the wheel assembly back to the girder, rolling the
wheel assembly along the trolley rail back to the original position.
11. Lower the hydraulic jack slowly, make sure the wheel assembly align with the
mounted plate of the trolley frame.
12. Fasten the connecting bolts between wheel assembly and trolley frame as
shown in figure 2.5.4.6-2
43
13. Install the sleeve on the drive end of wheel shaft as show in figure 2.5.4.6-1,
connect the sleeve with universal shaft, fasten the bolt.
14. Make sure all bolts are fasten to the specified torque. Clear the girder and
trolley area.
15. Running the trolley slowly, keep observing the new wheel until every thing is
OK.
DANGER! THE PERSON ON THE GROUND SHALL PREVENT FROM
HITTING BY THE COMPONENTS FALLING DOWN.
DANGER! WHEN THE TROLLEY IS RUNNING, KEEP AWAY FROM THE

TROLLEY MECHANISM, DO NOT TOUCH ANY ROTATING
COMPONENTS. ALL THE PERSON ON THE TROLLEY SHALL BE
PROVIDED WITH SAFE BELT.
2.5.5 Horizontal wheel system
2.5.5.1 Composition of horizontal wheel system
44
Figure 2.5.5-1 Horizontal wheel system
Horizontal wheels ensure that the trolley traverses along the rail track in a correct
way. Please see figure 2.5.5-1 for composition of horizontal wheel system. The
horizontal wheel system consists of supports, eccentric shafts, horizontal wheels,
bearings and seals etc. They are in two complete sets, fitted on appropriate
horizontal wheel bracket. Horizontal wheels contact the side surface of the rail
head to ensure the trolley is aligned with the rail during traversing. Since a certain
tolerance is permitted for the rail installation, the eccentric shafts of horizontal
wheels must be adjusted to ensure the horizontal wheels pass through every
section smoothly. The minimum clearance between the horizontal wheel and the
rail side surface should be not less than 3mm. After a certain time of running the
horizontal wheels and rail head side surface may be worn, and in this case the
clearance should also be adjusted through the eccentric shafts.
Horizontal wheels are made from No. 45 forged steel, quenched and tempered
surface that ensures wear-resistance. Horizontal wheels are subject to heavy
shock and frequent vibration, therefore, the bolts should often be checked for
loosening and tightened. If abnormal noise is found during trolley traversing, the
working condition and clearances shall be inspected. Horizontal wheels shall be
replaced when wear of wheels reaches 3 mm.
2.5.6 Trolley travel limit switch arrangement
2.5.6.1 Composition of trolley travel limit switch arrangement
45
The trolley travel limit switch arrangement consist of magnetic L.S.(for reduce
speed), and mechanical L.S.(for over travel stop). Before trolley arrived at rated
travel range, the speed of trolley will be reduced; When trolley arrived at rated
travel range, the trolley will be stopped by PLC control; The trolley will be stopped
by mechanical over travel L. S. in case of normal stop is failed.
Figure 2.5.6-1 Trolley travel limit switch arrangement

Period: routine
(2) Limit switches
Check whether the securing nuts of the limit switches are loosened.
Check whether their position has shifted.
Period: routine
2.5.7 Spreader slewing and trimming device
46
2.5.7.1 Composition of slewing and trimming device and its function
Figure 2.5.7-1 Spreader skewing and trimming device
Please see figure 2.5.7-1 for composition of spreader skewing device. The skewing
device is located near the hoist reducer and consists of an electric-hydraulic thruster
of DYTD5000-900/25ZAS lever system, etc. The spreader is skewed horizontally by
the forward and backward movement of the thruster. Skewing is controlled by
pressing the push-button in the operator's cab.
Skewing is done for easier spotting of the spreader. The spreader can be skewed on
the horizontal plane by  50 at 4m above the ground. It should be noted that the
spreader will be skewed by different maximum angles depending on its lifted height.
When it is necessary to skew the spreader, press the selector switch left or right and
the thruster moves forward and backward to skew the spreader. After the spreader
has been skewed, press the reset switch and spreader will be returned to its original
position.
47
The trimming  2.50 movement should be done by two thrusters at the same time.
Trimming is also controlled by pressing the push-button in the operator's cab.

After a long period of non - operation or after disassembly and re - assembly the
Crane shall be first run with no load allowing the reducers, bearings, etc. to be
lubricated fully, then operation with load can be started.

(1)Oil (grease) supply
During oil (grease) replacement the old oil (grease) shall be discharged thoroughly.
Grease shall not be mixed because mixed grease may result in bearing damage.
then once per month check all the bolts and re - tighten them. Pay special attention
to those securing bolts that may easily be neglected.
Check that lubrication is correct
Lubrication shall be done in accordance with the lubrication schedule.
Period: routine
(3) Sheaves
Check whether the sheave bearing is overheated. It is necessary to inspect the
inner part if the temperature of the casing is higher than the ambient temperature
by 40C.
Check whether bolts on the hollow cover are loosened and if the rope groove is
worn.
Period : routine
(4) Limit switches
Period : routine
48
2.5.8 Antisway system
2.5.8.1Composition of the sway - damping device
Figure 2.5.8-1 Antisway system
49
Figure 2.5.8-2 Antisway drive device
Please see figure 2.5.8-1 & 2.5.8-2 for composition of antisway system. The sway -
damping device is under the trolley frame. It consists of sway - damping wire rope,
drum, brake and inverter motor. This device is able to damp the spreader sway due
to the trolley acceleration and deceleration.
2.5.8.2 Arrangement and Principle

To reduce the spreader sway, in addition to the wire rope sheaves arrangement,
there is a device including inverter motor, gear reducer, chain transmission, drum
with clutch and brake. The one- way bearing functions to enable the drum to turn
only in the direction of winding up the wire rope. For paying out of the rope the
drum is engaged with the transmission shaft. The inverter motor is energized
constantly during Crane operation and thus the sway - damping wire rope is always
tensioned. That ensures the wind up of the slacked sway - damping wire rope
onto the drum. When the spreader sways, the disc brake connected on the drum
shaft provides a certain force to the tensioned rope to resist the spreader sway.
This resistant force may easily be adjusted through the spring setting. The inverter
motor winds up slackened rope and the above-mentioned action is repeated
several times to continuously reduce the sway.
50
2.5.8.3 Sway - damping
The brake in this system is released during hoisting and lowering and is applied
when the main hoisting is stopped and when trolley and gantry are in operation.
1.. During headblock lowering
Under the weight of the spreader each inverter motor is subject to a reverse force,
and the inner and outer rings of the one - way bearing are engaged with each
other. The brake is released and the shaft is revolving, and the tension force in the
sway - damping wire rope is the stall force of the torque motor. In this case sway
- damping device has a little effect.
2. When headblock is stopped
At the instant when the headblock is stopped and the brake is applied, the inner
and outer rings of the one - way bearing are disengaged from each other, and the
shaft is not revolving. If the spreader sways due to any other reason the brake
resists the spreader sway.
3. When the headblock is lifting
The headblock weight is not effected on the wire rope, and the inverter motors
drive the drum to wind up the rope. In this case, the inner and outer rings of the
one - way bearing are disengaged from each other and the revolving force is not
imposed on the shaft and the brake has no effect.
4. Trolley in operation (or simultaneous operation of the trolley and hoisting ),
gantry in operation.
During the trolley running (or simultaneous operation of trolley and hoisting ) and
gantry traveling, when the brake is applied the inner and outer rings of one - way
bearing are disengaged from each other and the shaft is not revolving. In this case
if the spreader sways due to some reason, the inverter motor winds up
continuously the slackened wire rope that reduces the spreader sway.

After a long period of non - operation or after disassembly and re - assembly the
Crane shall be first run with no load allowing the reducers, bearings, etc. to be
lubricated fully, then operation with load can be started.
51
2.5.8.5Inspection Items and Period for Maintenance
During oil (grease) replacement the old oil (grease) shall be discharged thoroughly.
Grease shall not be mixed because mixed grease may result in bearing damage.
Period : routine
(3) Sheaves
Check whether the sheave bearing is overheated. It is necessary to inspect the
inner part if the temperature of the casing is higher than the ambient temperature
by 40C.
Check whether bolts on the hollow cover are loosened and if the rope groove is
worn.
Period : routine
(4)Reducer
Please refer to Nord anti-sway sway reducer manual.
(6) Brake
Please refer to “ZPMC YP21LZ anti-sway brake manual”.
52
2.5.9 Operator's cab
2.5.9.1Composition of the Operator’s cabin
Figure 2.5.9-1 Operator’s cabin
The operator's cab is attached to the extended support beam of the trolley frame
with bolts and cushioning pads. The left side of the cab is connected with the
cable chain system. When the trolley traverses, it drags the cab and cable and
allows the operator a clear view of the container handling.
The operator's cab is 2.4m long and 2.2m wide and has window glass in front and
rear, and both sides as well as the front lower part of the cab. The glass is
laminated safety glass. The cab provides an excellent view and has good natural
light. The cab is spacious enough for easy cleaning. The operator's seat is located
in the front central part of the cab. The seat is designed on the basis of ergonomics
53
and is adjustable forward and backward, up and down. The backrest may be
adjusted within a wide angle range. The seat is cushioned and is soft and
comfortable. The control console is on the left and right hand sides in the cab.
Various electrical instruments and gauges, wind speed indicator, load indicator and
all operation instruments are arranged for convenient operation. The operator's
cab is provided with air conditioning, speakerphone, telephone and public address
system. The safeguard bars are fitted in front of the operator's seat and rear in
case of emergency braking.
2.5. 9.2 Inspection Items and Period for Maintenance

attention to those securing bolts that may easily be neglected ( i.e. the connecting
bolts between trolley frame and cabin).
(2) Check the glass of the windows
Keep all windows clean to provide good sight. Check if there is crack or other
abnormal conditions on the glass especially floor windows.
Period : routine.
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2.5.10 The Power Unit
2.5.10.1 Composition of the Power Unit
Figure 2.5.10-1 Power unit
The power unit of the Crane consists of the diesel engine Model QSX15-G7 by
CUMMINS, U.S.A., and an alternator HCI634 G1 by STAMFORD. Horse power of
the diesel engine is 620 BHP (prime power), and the alternator has power of
823KVA. The diesel engine - alternator set supplies power to every movement
mechanism and can meet the power requirement for hoist and trolley
simultaneously operation. The engine generator set has a common base frame so
that they can be removed by the forklift as a whole unit ease for maintenance. The
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fuel tank is in the sill beam with capacity of about 1600L (up to the top level on the
fuel level indicator).
The engine starting, accelerating, stopping may be controlled either in the engine
room or from the operator’s cab.
The engine is provided with protection from overheating of cooling water, low
pressure of lubrication oil, overspeed and frequent starting, etc. When the water
temperature is too high or lubrication oil pressure is too low, the fuel throttle
(accelerator) is shut off and acoustic and visual alarms will be sent to the
operator’s cab. The starting time shall not exceed 30 seconds for one time or less
than 5 times of 10 seconds. When engine is too frequently started, it is
automatically protected, i.e., the engine may be started again only after 2 minutes.
Also it may be started only after 2 minutes after the engine has been stopped.

No. 0 light diesel oil shall be used for the engine normal starting.

1.Make a record of water temperature, oil pressure, etc. daily.
2 The air filter, lubrication oil filter and fuel filter shall be checked and replaced refer
to the manufacturer’s manual.
3 Maintenance of the engine and alternator shall be done in accordance
with the Instructions for the diesel engine and the alternator.
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2.5.11 Cable Energy Chain System
2.5.11.1 Composition of cable energy chain system
Figure 2.5.11-1 Power chain system
Cable chain system consist of cable, cable channel, cable chain, guide roller and
tow frame etc.. Control power of the main hoist, trolley traversing, spreader
skewing and the power for the spreader is supplied through IGUS energy chain
system. Following the trolley traversing, the cable chain traverses to extend or
retract the cable. One end of the cable chain is fixed to the girder, and the other
end is fixed to the trolley, and the cable is led into the junction box on the
operator’s cab.
2.5.11.2 Points for Attention for Maintenance

Frequently check bolt connections and fastening by bolts and re - tighten bolts if
they are loosened.
For details, refer to the Instructions from IGUS
57
2.5.12 Spreader
For details, refer to the Instructions from RAM.
2.5.13 Headblock
2.5.13.1 Composition of headblock
Figure 2.5.13-1 Headblock
The headblock consist of structure, cable basket, sheave box, sheaves, ladder,
junction box, twistlock mechanism, lamp, nameplate etc.. The wire rope
connected to the spreader through headblock.

During oil (grease) replacement the old oil (grease) shall be discharged
thoroughly. Grease shall not be mixed because mixed grease may result in
bearing damage.
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Frequently check bolts for loosening, particularly after the first week of
running and then once per month check all the bolts and re - tighten them.
Pay special attention to those securing bolts that may easily be neglected.
Period : routine
(3) Sheaves
Check whether the sheave bearing is overheated. It is necessary to inspect
the inner part if the temperature of the casing is higher than the ambient
temperature by 40C.
Period : routine
(4) Limit switches
Period : routine
2.5.14 Stairs, platforms and ladders

2.5.14.1 Composition of stairs, platforms and ladders
See figure 2.5.14-1, the crane access consist of ladder to E-house and engine
room, cable chain system platform, girder platform, platform to cabin, engine set
foldable platform, emergency ladders, etc.. The platforms and stairs are provided
with hot dip galvanized grid plate which is anti slipping. Platforms, handrails, stairs
and ladders are all hot dip galvanized. The stairs are connected with platforms
through pins. There is foldable platform at inside of the engine house, during
maintenance, this platform can be put down for maintenance; during crane
operation, this platform must be folded up to increase inner side space. At
Electrical house side, there is a main passage from ground level to girder and
trolley;
59
Figure 2.5.14-1 Stairs, platforms and ladders

Period : routine
2.5.15 Other auxiliary devices

2.5.15.1 Jib Crane
At the end of the electrical house and cable chain side end, there is a ZPA-DY type
jib crane mounted for maintenance use. The main data of jib crane is as follow:
1. Brand of chain hoist DY5S-500
2. Type of chain hoist DY80M8/2;
3. Rated load SWL500kg
4. Hoist height 28.8m
5. Hoist speed 8/2 m/min
6 Rotating range 320°
60
Figure 2.5.15.1-1 Jib crane
For detail, please refer to the instructions from ZPA-DY.
2.5.15.3 Trolley anchor device

2.5.15.3.1 Composition of trolley anchor device
At two sides of trolley, there are two sets of trolley anchor devices. It consist of
anchor pin, limit switch, anchor points on girder and trolley center indicator. If the
trolley is anchored, the trolley can not move. If the trolley is out of operation, the
trolley shall be anchored properly.
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Figure 2.5.15.3-1 Trolley anchor device
2.5.15.3.2 Inspection Items and Period for Maintenance

then once per month check all the bolts and re - tighten them. Pay special attention
to those securing bolts that may easily be neglected.
Period: routine
2.5.15.4 Parking model for gantry

Under no operation，gantry should be parked as the below drawing to withstand
the wind，turn the gantry of two corners to 90 degree.
Figure 2.5.15.4-1 Parking model for gantry
2.5.15.5 RTG tyre pressure monitoring system (TPMS)
The RTG TPMS consists of sensor, repeater, and master. Sensors installed on
each tyre to get the pressure of tyre; Totally four repeaters, two installed at inside
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of sill beam, two installed at inside of girder; The master is installed in the cabin. If
the pressure of tyre is abnormal, there will be alarm on the master.
Figure 2.5.15.5-1 RTG TPMS
For detail, please refer to use manual for RTG TPMS.
Chapter 3 Crane Inspection, Maintenance and Repair

CHAPTER 3.
3.1 Crane Travel Operation

3.1.1 In non - operational conditions the trolley shall be anchored.
3.1.2 The Crane traveling is controlled with operation switch and limit switch
interlocks; therefore, the control parts such as limit switches shall not be removed
without permission.
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3.2 Management
3.2.1 The Crane shall be operated in accordance with operation Manual for the
Electrical System” since the electrical devices are controlled through the PLC and
ZPMC Siemens system.
3.2.2 Before operation the activation of limit switches for every mechanism shall be
confirmed to be accurate.
3.2.3 Pay close attention to the fastening bolts of every mechanism to ensure that
they are not loosened. Particular attention should be paid to the securing bolts
on the main hoist mechanism and on the spreader for safe load lifting and
lowering.
3.2.4 Pay attention to the brake disc and brake shoe pads which are easily worn
out parts in comparison with other parts. In addition, clearance between the brake
disc and brake shoe pads shall be kept between 0.51mm and 1.0 mm.
3.2.5 Frequently check that the remaining wraps of the main hoist wire rope on
the drum are more than two. Check whether the rope clamp bolts on the drum
are loosened and re - tighten them if necessary. Bolt loosening may result in the
wire rope falling.
3.2.6 Malfunction of the limit switches due to wire rope stretch should be corrected
through adjustment of the rope length. Particularly after rope replacement the new
wire rope may be stretched after a certain time period of operation and , therefore,
for the first stage of operation of new wire rope more frequent inspection should be
made.
3.2.7 The wire rope lubrication shall be checked every day and lubricant added if
necessary.
3.2.8 Replace parts when they are worn to the permitted limit.
3.2.9 Carefully check the wire rope end securing bolts, especially the following
bolts and re - tighten them:
3.2.9.1 Securing bolts on wire rope clamps on the drum;
3.2.9.2 During wire rope replacement care must be taken not to damage the thread
on the bolts for the rope clamp because with damaged thread the bolts can not be
tightened to adequate torque. Also take care not to damage the threads on other
bolts of the mechanical devices.
3.2.10 After installation has been completed or after re - tightening, loosening of
some bolts in mechanical parts may result in misalignment, vibration, heating, etc.
That may cause reduction of service life of the corresponding components or may
be the cause of running failure.
3.2.11 Routinely re - tighten bolts, nuts , etc.
Re-tightening operation of bolts and nuts:
After7 After 14 After 1 After 3 After 6 After 1

days days month months months year
Motor securing bolts 0 0 0
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Brake securing bolts 0 0 0
Brake disc nuts 0 0 0
Reducer securing bolts 0 0 0
Shaft system securing 0 0 0
bolts
Mechanical base frame 0 0 0 0
securing bolts
Wire rope securing 0 0 0 0
bolts on the drum
Wire rope clamp bolts 0 0
Connectors in the 0 0 0
control cabinet
Connectors of the 0 0 0
resistor grids
Connectors in the 0 0 0
operation box
Connectors of limit 0 0 0
switches
Items above with marks “0” shall be inspected and re - tightened in the
specified time interval.
3.3 Maintenance and Inspection
Maintenance of the crane is done to ensure good crane performance and to prevent
accidents.
Maintenance includes routine maintenance and regular inspection. In addition, in
case of typhoons or earthquakes it is necessary to inspect and confirm precautions
taken and to inspect after these events.
3.3.1 Points for Attention for Maintenance, Inspection and Repair
3.3.1.1 Before operation of the Crane the Operation Instructions for the Crane by
the manufacturer shall be thoroughly read and the operating records shall be
checked.
3.3.1.2 During maintenance, inspection or repairing the following matters must be
observed in addition to contacting related authorities:
3.3.1.2.1 If there is a Crane nearby, the anti - collision device must be carefully
inspected to prevent collision.
3.3.1.2.2 During maintenance, inspection or repairing a sign “under Repair” shall be
posted at a conspicuous place under the Crane to protect personnel from injury.
3.3.1.2.3 If it is necessary to inspect while the Crane is in operation, it is strictly
prohibited for any personnel to stand or pass under the spreader.
3.3.2 Record of Maintenance and Inspection Results
The following maintenance and inspection records are attached to these
Instructions. The results are necessary for the Crane repairing and modification and
shall be carefully recorded.
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3.3.2.1 Routine Inspection Items
3.3.2.1.1 Confirming performance and ambient safety before operation.
3.3.2.1.2 Observe the Crane’s condition and stop operation after any abnormal
condition is found.
3.3.2.1.3 After operation has been completed, the Crane shall be stopped at the
correct position and it should be confirmed that there is no abnormal condition.
3.3.2.1.4 Before starting operation
Inspection Items Inspection Method

1.Obstruction within traveling range and the load traveling Visual
path
3. Obstruction on trolley rail track Visual
4. Wire rope jumping off the drum or sheave or contact of Visual
the rope with any obstruction
5. Lack of lubrication in wire rope, strand breakage, loosening Visual
of clamp bolts
6. Inspection of brake pads Visual
7. Remedied condition of the defects found on previous day Activation
8. Inspection of brakes Starting
9. Various instrument panels and indicator lamps Starting
10. Activation of various operation joysticks and button Starting
switches
11. Activation of major limit switches (main hoist, trolley, Starting
spreader)
3.3.2.1.5 During operation

1. Abnormal sound, heating, vibration Visual
2. Abnormal current, voltage Visual
3. Activation of the spreader Visual
3.3.2.1.6 After Operation

1. Inspection of spreader Visual
1.1 Deformation and fracture of base frame Visual
1.2 Deformation and fracture of twistlock pins and flippers Visual
1.3 Damage and torsion on spreader cable Visual
1.4 Loosening of securing bolts Visual
2. If the various joysticks return to off position Visual
3. If various bearings, gears and other lubricated parts are Activation
normal
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4. Any abnormal heating Visual
5. Any fracture or damage on various components Visual
6. If the power switch is disconnected Starting
7. If power pack is switched off Visual
8. If various components are clean Visual
9. If the operator’s cab door is locked Visual
10. Operation log and record of container handling for shift
transferring
3.3.2.2 Items Inspected per week

The objective of this inspection is to find out defects between monthly inspections.
Inspection Time Inspection Items Inspection Method

After operation 1. Any loosening of bolts and Visual
damage of bearings
2. Any loosening of various pins, key Visual
boards and end stopper boards
3. Any torsion, damage, cracks of Visual
festoon cable and any loosening,
corrosion of terminals
4. Activation of electro - magnetic Activation
contacts, knife switch, etc.
3.3.2.3 Items Inspected every month, every year

The objective of regular inspection is to inspect the major parts of the Crane in
detail and to propose disassembly and repair when necessary and to find out
troubles which are not found during routine and weekly inspection and propose
repairing. Regular inspection is divided into monthly and annual inspection.
Category Monthly Inspection Annual Inspection

Inspection Items Inspection Items
Steel 1. Loosening of securing bolts 1. Corrosion of steel
structure 2. Fracture of welds 2. Peeling off of coating
3. Deformation, fracture of steel 3. Wear of shafts, pins
4. Grease for shafts, pins
5. Loosening of bolts on stairs,
handrails, platforms
Trolley 1. fracture of bolts 1. Rail span
rail
2. Loosening of connection 2. Elevation difference
boards between the two rails
3. Rail end wear and sinking 3. Bending in vertical
direction
4. Bending in horizontal
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direction
5.Slope
6. Misalignment of rail
joints
7. Damage and corrosion
of end bumpers
8. Damage and corrosion
of rail
Mechanical Gearing 1. Abnormal noise, abnormal 1. Cracks of casing
heating, abnormal vibration
2. Condition of teeth washing 2. Loosening of the key
3. Lubrication 3. Deformation of the key
slot
4. Oil level, oil leakage 4. Contamination of oil
5. Loosening of securing bolts
Bearings 1. Abnormal noise, abnormal 1. Any cutting scrap in the
heating oil (grease)
2. Damage or fracture of the 2. Clearance between the
body pin and bush
3. Loosening of securing bolts 3. Wear of the bearing
Shaft 1. Wear, fracture
2. Loosening of the key
3. Deformation of the key
way
Key 1. Deformation
Gear 1. Abnormal noise, heating 1. Alignment
coupling 2. Oil amount (grease) 2. Supply of oil (grease)
3. Oil leakage 3. Teeth backlash
4. Loosening of securing bolts 4. Loosening of the key
Mechanical 5. Deformation of the key
way
6. Damage of fracture of
teeth
Wheel 1. Wear, deformation of the
tread surface
2. Bolts loosening
Drum 1. Loosening of wire rope fixing 1. Wear on the rope
groove
2. Damage to the wire rope
guide
3. Damage to drum securing
bolts
4. Fracture of welds
Sheaves 1. Revolving condition
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2. Fracture
3. Rope groove wear
4. Damage to wire rope anti-
slipping device
Wire rope 1. Broken wires in strand
2. Wear and external damage
3. Bending, deformation
4. Strand loosening
5. Greased condition
6. Rust and corrosion
7. Fixing condition of wire rope
end
Spreader 1. Deformation and fracture of 1. Wear of the pins, shafts
the base frame etc.
2. Damage, deformation and 2. Peeling-off of coating
wear of twistlock pins, flippers
3. Loosening of securing bolts 3. Corrosion of steel
4. Center to center of twistlocks
5. Activation
Grease 1. Contamination of grease and
ageing, discolor of grease
supply 2. Grease supply at lubrication
points
3. Damage and oil (grease)
leakage in piping
3.3.2.4 Inspection Items after a storm

After a storm or earthquake the Crane shall be inspected.
Inspection Items:
3.3.2.4.1 Any obstruction within the Crane’s traveling range ?
3.3.2.4.2 Is stowage device in normal condition?
3.3.2.4.3 Were the traveling motors and brakes immersed in water?
3.3.2.4.4 Were the stairs, walkways and handrails damaged?
3.3.2.4.5 Any deformation or fracture of welds on structural members?
3.3.2.4.6 Did wire ropes jump from grooves of sheaves and guiding rollers?
3.3.2.4.7 Any damage to wire ropes?
3.3.2.4.8 Any interruption of oil (grease) supply system ?
3.3.2.4.9 Any damage, rain water in operator’s cab, engine room and electrical
room?
3.3.2.4.10 Is diesel-alternator set normal?
3.3.2.4.11 Is insulation resistance value reduced?
3.3.2.4.12 Any damage to lighting fixtures?
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Points for Attention after Inspection
3.3.2.4.13 Add oil (grease) to all oil (grease) supply points
3.3.2.4.14 Run each movement with no load.
3.3.2.4.15 Confirm activation of every limit switch.
3.3.2.4.16 When it is confirmed that there is not any trouble or obstruction in
operation, the Crane may be put into normal operation.
3.4 Preparation of the Crane
3.4.1 When starting operation the Crane shall be run first without load and the
action of brakes, bolts ,etc. shall be inspected.
3.4.2 Frequently check the operation joysticks and keep them clean. Frequently
grease each sliding part.
3.4.3 For motors, electro-magnetic brakes, resistors, thrustors, operation joysticks
etc, refer to operation Instructions for Electrical Parts.
3.5 Lubrication of the Crane
3.5.1 General
3.5.1.1 Frequently replenish oil in the gear reducer to keep the oil level within
specified range. When the oil is contaminated, it should be replaced.
3.5.1.2 At least more than once per month grease all the lubrication nipples until all
the old grease is pressed out.
3.5.1.3 Properly grease connection pins. For moving auxiliary devices without
grease nipples, drip oil with oil can.
3.5.1.4 Brake pads and electrical connectors shall not be greased (oiled).
3.5.2 Points for Attention for Lubrication
3.5.2.1 Lubrication materials must be kept clean.
3.5.2.2 Lubrication greases of different brands shall not be mixed.
3.5.2.3 Frequently check sealing of lubrication system.
3.5.2.4 Select appropriate lubrication materials and lubricate according to the
specified schedule.
3.5.2.5 Lubrication shall be carried out when Crane power is off.
3.5.2.6 For revolving parts without grease fittings, the oil can shall be used to drip
oil into the clearance for reducing wear and prevention of rusting .
3.5.2.7 Periodically check quality of oil where components and parts are lubricated
through oil bath.
3.5.2.8 For grease lubricated points, the old grease shall be discharged as much
as possible and then the fresh grease may be added.
3.5.3 Crane lubrication schedule
Note: The user may carry out frequent maintenance and inspection in accordance
with his effective practice or the local regulations to ensure the Crane’s normal
operation.
Crane Lubrication Schedule
70
Sg.No Description Lubrication Lubrication Lubrication
period type material
1 All wire ropes Normally 15-30 Heat the lubricant Wire rope fibre
days (grease) to 80- core grease,
100C and compound sodium
immerse the rope - based graphite
to saturation lubricant or other
grease
2 Main hoist Change oil after Oil bath
reducer 400 hrs. of first
Refer to main hoist
running, then
reducer manual.
change oil every
5000hrs running
3 Trolley Change oil after Oil bath
Refer to trolley
running, then
reducer manual.
change oil every
5000hrs running
4 Gantry Change oil after Oil bath
Refer to gantry
running, then
reducer manual.
change oil every
5000hrs running
5 Rolling High speed Operation Any element-
bearing and end: once per temperature based lubricant
gear coupling month -20-50C
Low speed end:
3 - 6 months
6 Plain bearing High speed end: Operation Industrial lithium-
once per day temperature based lubricant
Low speed end higher than 50C
once per week
Add grease fully
at each time of Operation
overhauling temperature Use No. 1, 2
lower than -20C special grease
7 Electrical Annual repair or General motor Compound
Motors overhaul insulation or aluminum-based
tropicalized grease, No.3
lithium-based
grease
8 All point Three months Pins HC 20 mechanical
points of oil
brakes, limit
switches,joys
ticks
9 Main hoist Six months Lithium--based
command grease
limit, Open
gearing,
Hinged pin of
universal
coupling of
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the trolley,
Gantry open
chain trans-
mission
10 All sheaves’ Three months Grease nipples Lithium--based
shafts grease
3.6 Common Troubles and Troubleshooting for the Crane
3.6.1 Classification of the Crane Troubles
The Crane is used for lifting and handling goods. It is used widely in modern
industry, transportation and capital construction. However, after a certain period of
operation some troubles may appear due to wear and increase of clearances or
fatigue of some major member or components. Therefore, the Crane operators
must learn to recognize common troubles and immediately repair the defective
members and components to ensure the Crane’s safe operation.
3.6.1.1 Trouble in mechanical part
Any assembly consists of a number of parts and components and these

assemblies form the mechanism of the Crane. Mechanical trouble with the RTG
occurs mainly in the diesel engine alternator set, motors, brakes, reducers, sheave
blocks, drum, spreader, couplings, traveling wheels , etc. Surface wear occurs
during their movement , and when the wear reaches a certain value the Crane’s
operation may be affected.
Brakes are one of the essential components on the Crane and their
performance governs the accuracy of each movement and safety of operation.
For the main hoisting the brakes must be absolutely reliable. The brakes
should be inspected at every shift and adjusted if the clearance is found to be
excessive. Troubles with the brakes are mainly due to poor action of the
transmission system, jamming of the pivot pins, worn out parts unreplaced or the
clearance between the brake pads and brake disc is improperly adjusted .
Sometimes failure of the brakes results from trouble with the hydraulic thruster or
the brake size is inadequate with too small a braking torque.
In a Crane the reducers are used for main hoist, trolley traversing and gantry
traveling to transfer the mechanical torque and to reduce revolutions. The
performance of reducers directly affects the Crane’s safe operation. After a long
period of running, the teeth surfaces may suffer fatigue, pitting and wear that
results in abnormal noise, vibration and heating. Therefore, if any defects are found
in the reducer, they must be eliminated immediately.
The couplings are also used for torque transfer but the speed is unreduced.
Couplings are divided into rigid couplings and flexible couplings. Wearing results
72
from poor installation with misalignment between the two shafts coupled and poor
lubrication. Serious wear of the teeth on the gear coupling may cause failure of
transmission and/or serious accident.
The most common trouble with the sheave and drum is wear of the rope
grooves. The reason is that during no-load running the wire ropes in the grooves
are slackened and when operation with load is started the wire ropes are tensioned
and press the rope grooves with a certain pressure. Therefore, during hoisting or
lowering slip between the wire rope and the groove of sheave and drum occurs. In
addition, since the wire rope has a fleet angle to the rope groove the rope groove is
seriously worn at its tip. The sheave and / or drum shall not be used any longer if
cracks are found or the grooves are worn to the permitted limit. Seriously worn
grooves may make the rope jump out of the groove, and the broken rim of the
sheave may damage the wire rope or jam the rope and finally result in breakage of
the rope.
3.6.1.2 Trouble in the steel structure
The quality of the Crane structure directly affects Crane safety. Once the structure
is damaged a serious accident may occur. Therefore, the Crane steel structure is
designed to meet the strength, rigidity and stability requirements.
If cracks appear in the welds, the Crane may not be operated normally and safe
production may be affected.
3.6.1.3 Trouble in the Electrical Part

Motors are required to have great mechanical strength and high overload
capability . They are subject to frequent mechanical vibration and shock and they
shall have small moment of inertia to be started and braked rapidly. There should
not be any noise due to friction, any shrill sound or other noise during motor
running , and they should be stopped for repairs if these noises appear. Water
and oil shall not be dripped into the motor during operation. The troubles with the
motor mainly are disabling of starting, high temperature rise and that the power can
not reach rated value during running with load.
Electrical equipment is a more complicated part of the Crane, and it is easily

affected by shock and vibration, especially in an ambiance of high temperature,
dust, and high humidity. Failure of the electrical equipment results not only in
stopping of production but also accidents.
Electrical equipment on a Crane includes motors, electrical magnet, controls,
resistors and other components such as conductors, slip ring devices and various
control circuits. For details refer to the Electrical Operation Manual.
3.6.2 Causes of Common Troubles and Troubleshooting
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3.6.2.1 Causes of general troubles in the Crane parts and components and their
remedies are shown in the following table:
Troubles Causes Remedy method
High temperature in Lack of grease or no Add sufficient grease
rolling bearing(s) grease
Contamination in the Clean the bearing with
bearing(s) kerosene and fill with
grease
Noise in rolling bearing Poor installation Check correctness of
is increased misalignment of the installation and adjust
bearing or over tightened
and jammed
Damaged or worn Replace bearing
bearing elements
Periodic chattering noise Excessive error of the Remedy, re-assemble
of the gearing in the teeth pitch. Teeth lateral
reducer, particularly from backlash exceeds
the idle gear wheel standard value
Sharp friction sound and Clearance of gearing is Remedy, re-assemble or
clatter sound in the too small, misalignment of replace
reducer the gear wheel, sharp and
thin edge on the teeth top,
teeth face uneven due to
wear
Uneven meshing, Defects on tooth lateral Replace
continuous knocking surface (laminated
sound heard from any texture)
point on the reducer
casing and vibration of
the reducer
Knocking sound in the Excessive axial backlash Replace
worm gear reducer, of the worm or the teeth
alternate high and low of worm gear are
and the period coincides seriously worn, pitch
with that of gearing circle of the gear is
rotation sound eccentric in relation to
the shaft, accumulated Repair or re-assemble
error of the circular pitch
of the gear
Heating of the reducer Lack of oil Oil temperature <60C for
cylindrical and bevel gear
reducer, and <70C for
worm gear reducer. Oil level
shall be kept between the
two pointer scales
High noise of shock in Excessive wear of gear Replace gear wheel
the gear reducer wheel
Foreign matter in the Remove the foreign matter
casing
Bearing is damaged Replace bearing
74
Bearing overheated in Contamination in bearing Disassemble and clean the
the reducer bearing
Too small clearance Adjust
Lack of grease (oil) Add grease(oil)
Brake(s) can not hold the Jammed pivot linkage in Clean up the brake element
load (excessive braking lever system jam and grease the pivots
distance of the trolley or
gantry)
Oil (grease) on the brake Clean brake disc and brake
disc or brake pads pads with kerosene
Excessive wear of the Replace brake pads
brake pads
Main spring damaged or Replace spring or adjust the
loosened results in nut to make the spring
insufficient tension tension sufficient
Loosening of the lock nut Adjust the lever and tighten
of the lever, lever’s play nut
Burnt spots on brake Uneven clearance Adjust clearance to make it
disc and rapid wear of between brake disc and even, replace auxiliary
brake disc brake pads, friction spring
appears when released
and the disc is heated,
auxiliary spring is
damaged or bent
Brake is easily deviated Adjustment nut is not Adjust brake tighten nut and
from the adjusted tightened or lock nut is lock nut, or replace defective
position not tightened, thread of nut
the nut is damaged
Rapid wear or frequent Contamination and lack of Clean and lubricate the wire
breakage of wire rope grease rope
Sheave does not rotate Lack of lubrication Disassemble and lubricate parts
between shaft and bush and add grease
Too long starting time of Too high resistant force at Clean up every pivot point
brake(s) various pivot points of and grease
brake(s)
Too low oil pressure or oil Clean piping and fill in with
piping blocked oil as necessary
Internal oil leakage Clean and check hydraulic
thruster for noise; damaged
parts shall be replaced
immediately
No pressure in hydraulic Orifice of pressure relief Clean pressure relief value
thruster, no braking value is blocked
The solenoid is reversely Adjust wiring
connected and the
thruster can not be
pushed downward
pump fitting is not Tighten the fitting of the
tightened pump
75
Filter is blocked Clean the filter
Pressure in hydraulic The plane of the control Find out the failure point and
thruster can not reach lever of the adjustable correct it
operating pressure value device of pressure relief is
not leveled; control lever
has deviated from the
center of nozzle
Too long braking time Insufficient current in the Increase current within
solenoid of electro- permitted range
hydraulic adjustment
device
Release time by the Small distance between Slightly tighten the upper
hydraulic thruster is too the control lever and the end nut of the cross-spring
long, residual pressure nozzle
too high
Too small diameter of the Enlarge the bore diameter

nozzle bore
The brake can not be Too high tension of the Adjust the tension of the
released main spring spring
Thruster is damaged Repair or replace hydraulic
thruster
3.6.2.2 Regular Inspection Items (Mechanical) for the Crane

Inspected Inspection Inspection Inspection Inspection
Components Items method criteria period
and
Sg. Descrip- Sg. Description apparatus
No tion No
1 Reducer 1 Lubrication Visual, with Indicated range per month
oil amount oil scale on the scale
2 Sealing Visual Fixed joint: no per month
leakage.
Relatively
moving joint: no
drip
76
3 Running Testing, no abnormal per month
condition hear and sound,
feel abnormal
heating
4 Bolt Knock and no loosening Per month
connection test
5 Oil quality chemical to specified by every
analysis standard season
6 Gear meshing Visual test Tooth face every
smooth and season
clean normal
meshing
7 Wear of gear Measure wear is less every year
wheel than 10% tooth
original
thickness
2 Drum 1 Wear of the Measure Wear is less every half a
drum shell than year
15%original
thickness
2 Wire rope Knocking no damages per month
clamp
3 Rope grooves Visual no damages
4 Fatigue Visual no damages per month
cracks
5 Bearing Visual Proper per month
lubrication lubrication
3 Wire 1 Lubrication Visual Grease is not per month
rope dried,distributed
uniformly

Components Items method criteria period
No. tion No.
2 Wear Measure Diameter per month
reduced by
<7%
3 Wire broken, Visual Broken wire per month
strand broken <10% no
strand is
broken
77
4 Torsion or Visual no torsion, per month
corrosion no corrosion
4 Sheave 1 Cracks Visual no cracks per month
2 Sheave rotation Hearing test maneuver- per month
able, no
abnormal
noise
3 Uneven wear of Measure less than every
the groove 3mm season
4 Wear of groove Measure 20% original every
thickness thickness season
5 Wear at groove Measure <50% wire every
bottom rope season
diameter diameter
6 Damage Visual no damage per month
7 Bearing Hearing, no abnormal per month
visual noise proper
lubrication
5 Brake 1 Brake base Visual no cracks per month
frame
2 Wear of Measure <50% per month
thickness of original
brake pads thickness
3 Spring Visual, no yield every
measure deformation season
4 Wear of shaft Measure <5% original per month
or bore diameter
5 Hydraulic Visual no oil drip, per month
thruster normal
activation

Components Items method and criteria period
No. tion No
5 6 Clearance Visual >0.6mm, per month
when released measure <1.5mm
7 Bolts, nuts Knocking test no loosening per month
hammer test
8 operation Testing and normal per month
condition observe operation,
reliable, no
78
abnormal
heating,
smell, and
action
6 Brake 1 Brake disc Visual no cracks per month
disc body
2 Wear in disc Measure <4% original every
thickness thickness season
3 unevenness of Measure <1.5mm every
disc surface season
4 Friction surface Visual no cracks per month
7 Coupl- 1 Coupling body Visual no cracks per month
ing 2 Pins Visual no damage, per month
normal wear
8 Wire 1 Wire rope end, Visual no abnormal per month
rope screw lever condition, no
suspen- cracks
sion
device
2 Bolt connection Visual, Normal, no per month
knocking test loosening
3 Wire rope Visual Normal per month
support rollers operation, no
deformation
at deport, no
cracks
9 Lubrica- 1 Grease amount Visual To meet per month
tion requirement
points
2 Quality of Visual To meet per month
grease(oil) regulation
. 3 Nipples and Visual No damage, every
tubing unblocked season

Sg. Descrip- Sg Description apparatus
No. tion .N
o.
10 Trolley 1 Wheel body Visual no cracks per month
wheels
2 Wear of wheel Measure <50% every
flange original season
thickness thickness
3 Bending Measure <20% every
deformation of original season
wheel flange in thickness
79
thickness
4 Wear of tread Measure <15% every
in thickness original season
thickness
5 Ellipticity Measure <1mm every
season
11 Rubber 1 Inflation Measure 10.0kg/cm2 per week
tyres pressure
2 Surface of the Visual no cracks per week
tyres
3 Wheel bearing Visual, testing Proper per week
lubrication,
no abnormal
4 Connection Visual, Normal per week
bolts knocking test condition, no
loosening
12 Diesel 1 Air fitter Visual clean per week
engine
2 Lubrication oil Check Foreign per month
matter and
water content
meets
standard
3 Water tank Visual no missing, per week
cover no damage
4 Diesel fuel tank Visual no missing, per week
cover no damage
5 Fan belt Test Tension per month

meets
requirement
6 Sealing Visual No leakage per week
7 Abnormal noise Hearing No abnormal per week
noise

No. tion .N
o.
13 Altern- 1 Carbon Test run, No sparks per week
ator set brushes & visual during
commutator running
2 Wear of carbon Measure Thickness per
brushes >20mm season
3 Pressure of Measure 1.8-2.0N/cm2 per
brush spring season
4 Resistance of Measure >1M in cold per
80
insulation state season
>0.5M in
hot state
5 Wire Visual, No damage, per week
connection knocking test no loosening
6 Filtered cover Visual No dust & per week
of the ventilator foreign
matter
7 Transmis-- Testing No defects, per month
sion bolt tension
meets
specified
8 Running Test run No abnormal per week
condition noise no
abnormal
heat
14 Trolley 1 Horizontal Visual No defects per month
horizon- wheel body such as
tal wheel cracks
2 Clearance Measure 2--3mm per month
between the
guiding rail
3 Bolt connection Visual, No abnormal per month
knocking test condition, no
loosening
4 Lubrication Lubricate Proper per month
lubrication
5 Wear Measure Meet per
technical season
requirement

No. tion No.
15 Gearing 1 Gear wheels Visual no cracks, no per month
teeth
breakage
2 Pitting on Visual <30% per month
teeth face meshing
face,
depth >10%
original tooth
thickness
81
3 Wear of tooth Measure GB6067-85 per year
thickness
4 Lubrication Visual Proper per month
lubrication
16 Univers- 1 Connection Visual, No loosening per week
al transm- knocking correct
ission
2 Lubrication Lubrication Proper per week
lubrication
3 Parts of shaft Visual No cracks per week
17 Chain 1 Running Visual No abnormal per week
sprocket condition inspection condition
and chain
2 Damage Visual No damage per week
3 Lubrication Visual Proper per week
lubrication
18 Bumpe- 1 Bumper body Visual No damage per month
rs & cracks
2 Support Visual No cracks, per month
knocking firm
connection
3 Spring Visual No abnormal per month
condition
19 Headbl- 1 Cracks, Visual, NDT No cracks, per year

ock damage no damage
twislock
2 Wear Inspection As technically per
required season

No. tion .N
o.
20 Spread- 1 Load bearing Visual, No damage per month
er Measure no wear
telesco-
pic
2 Rail Visual, No defects, per month
Measure wear within
permitted
range
82
21 Cable 1 Cable clamp Visual, perfect no per month
chain knocking loosening
2 Roller Visual proper per month
lubrication,
no damage
3 Support bracket Visual perfect per month
4 Bolt connection Visual, No loosening per month
knocking
5 Cable Visual no damage per month
22 Spread- 1 Plastic Visual No plastic per month
er deformation deformation
twistlock
2 Damage Visual no damage per month
3 Turning angle Testing 00, 900 per month
4 Wear Measure As per year
technically
required
5 Cracks Visual NDT No cracks per year

No. tion No.
23 Steel 1 Box- Painting Visual, No large per
structure section telescope area of season
members peeling off
Welds Visual, No cracks,
telescope ultrasonic
rulers and X-ray
test if
necessary
83
depth of
corrosion
<10% weld
height
Plate Visual, No
surface rulers cracks,local
deformation
<3%depth of
corrosion
<10%
2 Walkways Oil(greas Visual Normal per month
stairs e)conta- walking,
minated, No damage
damage
3 Railings Damage Visual No damage per month
Appendix 1: Wire rope

Type Diameter Broken force Q’Y Used place
(mm) (KN) (m)
IWRC 6xFi(29) - 25 25 423 295 JL3160603
(Bridon) Main hoist reeving
14-NAT-6X19W+FC- 14 123 144 JL3160604

1700-ZS (GB/T 8918- Anti-sway system
1996)
84
Appendix 2: Sheave
Type Diameter Q’Y Used place
(mm) (pc)
ZMHL760-A-1(RTG) 760 8 1. Main hoist reeving JL3160603

2. Head block
ZMHL480-A-1(RTG) 480 8 Main hoist reeving JL3160603
JL31606040501 400 8 Anti-sway system JL3160604
Appendix 3: Tyre
Brand Model Q’Y Used place
(pc)
ZPMC 21.00-25 40PLY 8 1. Gantry traveling mechanism

Tubeless JL31601
Appendix 4: Seal
Type Size Q’Y Used place
(mm) (pc)
GB 9877.1-1988 8010010 4 Guide roller JL3160610
HG4-692-67 406212 1 Hoist drum assembly

PD406212 JL316060801
HG4-692-67 13016015 1
PD13016015
HG4-692-67 14017015 8 Main hoist reeving
PD14017015 JL3160603
HG4-692-67 14017015 8 Head block
PD14017015
85
HG4-692-67 759512 16 Anti sway system
PD759512 JL3160604
HG4-692-67 9011512 6
PD9011512
JB/ZQ 4075-1997 Z130 130(inner dia.) 8 Trolley traveling mechanism
JB/ZQ 4075-1997 Z105 110 (inner dia.) 2 JL3160601
Appendix 5: Bearing
Chinese and SKF bearing comparative list
Model Dimension Q’y SKFType Used place
(mm) (pc)
GB/T 281-1994 7516055 4 2315 Anti-sway device
2315 JL3160604
GB/T 276-1994 9517032 4 6219-2Z
6219-2RZ
SKF/FAG 6512023 16 NJ213EC
NJ213E
GB/T 288-1994 7012531 8 22214CC/W33 Guide roller
22214CC/W33 JL3160610
SKF/FAG 11024080 8 22322CC/W33 Trolley traveling mechanism
22322 CC/W33 JL3160601
SKF/FAG 13023040 8 NJ 226 EC Rope reeving diagram

NJ226E JL3160603
SKF/FAG 13023040 8 NJ 226 EC Headblock
NJ226 E
SKF/FAG 12021558 1 22224 E JL316060801
22224 E Hoist mechanism
Appendix 6: Roller Chain

Chinese and ISO comparative list
Type Pitch ISO Q’Y Used place
86
(mm) (pc)
GB1243.1-1997 31.75 20A-1 66pitch4 Anti-sway system JL3160604

20A-168
Appendix 7: Brake lining

type Q’Y used place
Brake lining match with SB28-630x30- 2 sets Hoist mechanism
ED121/6 BUBENZER JL3160608
Brake lining 4 sets Integral with Siemens gantry
motor
Brake lining match with SB8.11-355x20- 2 sets Trolley traveling mechanism
ED23/5 BUBENZER JL3160601
Brake lining match with YP21LZ-800-630x30 2 sets Anti-sway system
ZPMC JL3160604
Appendix 8 : Lubricant grease

GREASE MODEL
Shell Alvania EP Grease R1 For bearing , pin connection, etc
Rexnord Falk LTG For drum coupling
SHELL Gadus S2 OG 80 For ropes
Appendix 9: Reducer Lubricant Oil
Reducer name Lubricant Oil Oil Q’Y
Hoist reducer shell Omala S2 G 320, oil ~250L
87
Trolley reducer shell Omala S2 G 320, oil ~30L
Gantry reducer shell Omala S2 G 320, oil ~45L*4
88

Mechanical Maintenance Manual For RTG

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RUBBER-TYRED GANTRY CONTAINER CRANES

Shanghai Zhenhua Heavy Industry Co., Ltd.

1.1 Warning and symbols

Special information and/or orders and prohibitions directed towards

Do not enter, Authorized personnel only.

Refers to information in other parts of the Manual

Keep hands clear of the moving parts.

Keep away from suspended loads

Keep hands and body clear

No access to the dangerous place

Before operating or maintaining the crane, the operation and maintenance

It is always a good practice to work in a team of at least two persons in a place

In addition to the operation and maintenance instructions provided herein, legal

IT’S ABOUT YOUR SAFETY!

Uncompleted or illegible operation and maintenance must be replaced

The operating and maintenance staff has to be checked by the employer

Arbitrary constructive modifications and the alteration of parameters beyond the

IMPORTANT SAFETY PRACTICE!

The following safety rules must be observed strictly in practice:

(5) Do not lubricate the components of the machine during operation.

1.4 Safety rules for operation

(2) Unauthorized persons should not enter the crane.

(4) The factory setting of the components must not be changed.

(6) Check for obstructions on the gantry runways.

(7) Check that lubrication for every mechanical part is sufficient.

(9) Check that power supply voltage is normal.

Precautions during service:

DANGER ZONE MUST BE BLOCKED BY SUITABLE MEASURES.

Cautions after service:

(1) Park the Crane at the assigned location.

1.5 Safety rules for maintenance and repair

Observe the following safety rules when conducting maintenance or inspection

(5) The crane should be in maintenance mode for such a task.

(12) Do not use the machine parts as climbing aids.

1.6 Conduct in case of accidents and emergency

2.1 General features of RTG Cranes

The typical dimensions of the Crane is able to pass across 6 rows of

The gantry frame of the Crane is of box-section welded construction. The

The operator should thoroughly read these instructions and should be

Figure 2.2-1 Crane general layout

As shown in Figure 2.2-1, the main composition of crane is as follow:

As shown in Figure 2-2.2, the main composition of crane is as follow:

1- Trolley travel mechanism

Item Value Unit Remark

The steel structure part consists of developing inspection procedures and

2.4.2 Test procedure

1. All bolted and welded joints shall be visually inspected (VT).

2.4.4 Reporting procedure

2. The side and extent of defect.

number, waterside, landside, distance in inches to nearest station, etc.

5. Method of testing: VT, MT, and UT.

6. Inspector's comments and signature

2.4.5 Inspection period

2.4.6 Typical repair procedure

8. Electrodes shall be in accordance with Table 3.1 of AWS

welded with electrodes with an AWS toughness rating of at least 20 ft-lbs at -

ALL PRECEPTS OUTLINED IN THE “Chapter 1 Safety” APPLY TO THIS

2.5.1 Gantry traveling mechanism

2.5.1.1 Composition of gantry traveling mechanism