Section 3: Maintenance instruction

 Cleaning
 Fastening
 Alignment
 Lubrication
 Inspection

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 Cleaning

 Method of the cleaning:

1. Using the cleaner: remove the dust and
small dirt from the body surface, usually
good for electric elements.
2. Air compressor: directly remove the powder,
iron chipping and other waste falling off from
body surface easily.
3. Wire brush: remove the flotation rust or do
the metal surface treatment before repairing
paint.
4. Machining: such as damaged brake pad or
disc.

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 Cleaning

Where need cleaning:

 General:
1. Brake disc and pad
2. Filter of motors, fans
3. Oil of gearbox, hydraulic system
4. Clean the obstacles on the rail of trolley and gantry
5. Gantry rail where is polluted by salt water
6. Window glass of operator’s cab
7. Indicator light

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 Where need to be cleaned:

 Electric system:
1. Transformer inside, especially surface of coiling.
2. Keep e-room clean. Do not keep the door open.
3. Electric elements inside the control panel shall
be cleaned regularly.
 Hydraulic system:
Hole for air drain
1. Prevent the dust and other contamination into
the oil.
oil filter
2. Prevent air into or drain the air from oil.
3. Prevent humidity into or drain the water from the
oil.
4. Checking and changing the filter of oil.

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 Fastening
Comparison of the ISO and SAE (society of automotive engineers) bolts and nuts

ISO898-1 SAE J429 ISO898-2 SAE J995

Bolt Bolt Nut Nut
Grade 4.8 Grade 1 4
Grade 5.8 Grade 2 5 Grade 2
Grade 6.8 6
Grade 8.8 Grade 5 8 Grade 5
Grade 9.8 9
Grade 10.9 Grade 8 10 Grade 8

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 Fastening
Visual inspection:

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 Fastening
Torque Wrench-For normal bolts:
1. Stow the crane. Make the bolts without working stress.
2. Mark the bolts and nuts. See the right figure.
3. Apply a 75 ％ final tight torque to the nuts.
4. Check if the nut is turning. In case of yes, marking the loosing nuts so that it
could be retighten later or be changed.
5. Repeating 2)~5) to check all the rest bolts.
6. Retighten all the loosing nuts according to the procedure later given.
7. Retighten all the nuts that do not turning in step 3~4 according to following
step 8~10.
8. Turn the nut anticlockwise about 30°to loosing the nuts.
9. Retighten the nuts to final torque.
10. Clean the surface and painting.

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 Fastening
Torque Wrench-For structure bolts:
1. Stow The crane.
2. Mark the bolt and nuts. See the right figure.
3. Apply a 75 ％ final tighten torque to the nuts.
4. Check if the nut is turning. In case of yes, marking the loosing nuts
so that it could be changed later.
5. Repeating 2)~4) to check all the rest bolts.
6. If more than 20% of bolts are marked to change, then change all the
bolt. If less than 20% bolts are marked, then the adjacent bolts of
marked bolts also need to change.
7. Retighten all the nuts that not turning in step 3~4 according to the
following step 8~9.
8. Turn the nut anticlockwise about 30°to loosing the nuts.
9. Retighten the nuts to final torque.
10. Clean the surface and painting.

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 Fastening
Frequency of inspection:

Inspection Frequency Frequency

（ Before first inspection ） * （ After first inspection ）
Visual 3 month （ except special 6 month （ except special
area ） area ）
Torque Six month or 50000 5 、 15 、 25 、 30 、 35ye
Wrench cycles ， 10 ％ spot check ars after operating
Changing the When it is need When it is need
bolts

＊ First inspection means six month or 50000 cycles, whichever come first.

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 Fastening
Standard of changing the bolts:
 Damaged, deformed, corrosive bolts, or the surface roughness vary
much.
 For structure bolts according to GB1228 、 GB1229 、 GB1230 、
ASTM325 、 ASTM490 or other equal standard, normal the
galvanized bolts could not be re-used after finally tighten.

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 Fastening
Tight the bolts-normal bolts:
1. Make sure that the washer is not polluted and in good condition.
2. Clean the dirt from surface between washer and structure. The
surface shall be level.
3. Clean the bolts and nuts .
4. Lay the washers so that it could well against bolt head or nuts.
5. Apply a torque of 75% final toque. For the connection of flange, pay
attention to the order of tightening to guarantee the bolt is loaded
evenly. Usually tightening start and spread from the most rigid points
.
6. Apply 100% final toque to the bolts. The tighten bolt shall be marked
with different colors for 75% torque and 100% torque.

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 Fastening
Tightening sequence (example of flange
connection):

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 Fastening
Tight the bolts-structure bolts:
1. All the bolts shall come from one production batch. It guarantee the
uniform friction properties.
2. Make sure there are sufficient number of bolts with correct grade.
The torque wrench shall be verified.
3. Make sure that the washer is not polluted and in good condition.
4. Clean the dirt from surface between washer and structure. The
surface shall be level.
5. Clean the bolts and nut.
6. Loosing one bolts and nuts completely and replace it with new one
and apply a 75% final torque. Make sure only one bolt and nut are
removed. Replace all the bolts one by one.
7. The removed bolts shall be damaged to prevent re-using .
8. Apply 100% final toque to the bolts. The tighten bolt shall be
marked with different colors for 75% torque and 100% torque. Pay
attention to the sequence of tightening.

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Fastening

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 Alignment

Standard of Alignment

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 Alignment
Coupling Δr （ mm ） Δb Δa （ mm ）
Location

MH motor coupling elastic ≤0.05 2’ ＝ Δr

BH motor coupling elastic ≤0.05 2’ ＝ Δr

TL motor coupling elastic ≤0.05 2’ ＝ Δr

MH drum coupling gear --- 10’ ---

BH drum coupling gear --- 10’ ---

In the first year that the crane is brought into service, the inspection cycle
should be shorter, e.g., once per three months. After the mechanism get
stable in the service, the inspection cycle can be lengthened suitably.

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 Alignment

Use the laser concentricity measuring instrument

1. The laser is fixed on one side of the coupling and the
receiver is fixed on the other side.
2. Input relative dimensions into the microcomputer, such
as the dimensions of the motor pedestal, and the
distance between the coupling center.
3. Before rotating, the initial value should be reset to zero.
4. Turning both the motor shaft and the reducer shaft only y
x
60°-75°. z
5. Both the angular deviation of δz and the radial deviation
of δy will show on the panel.
6. The microcomputer will automatically calculate the value
of displacement of the motor and the difference of the
shim thickness.
7. Add or reduce the shims to decrease the deviation in
elevation direction, adjust the fitting bolts or blocks for
motor pedestal to decrease the deviation in horizontal
direction.

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 Alignment
Use a dial indicator gauge

1. Set the gauge: gauge base is placed on one side of the coupling and the
indicator shall contact the outer ring of the other side of the coupling.
2. Initially, reset the reading to zero. So the values can be read after turning
270 (please note the positive and negative signs). Then got δ90°,δ180°,
δ270° , Δry=δ180°/2
3. The jumping value in the horizontal direction is ΔrZ=δ90°-δ270° 。 Same
as shown in the above drawing, make the indicator contact the shoulder
surface of the other side of the coupling and adjust the value to zero.
After turning 270, two angular deviations in the vertical and horizontal
axial directions can be read. Got δ90°,δ180°,δ270°Δay= δ180° ， ΔaZ=
δ90°-δ270°, Δby=arctg Δay /r, Δbz=arctg Δaz /r.

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Alignment

Estimate the thickness of shims under the motor base

and the distance should be adjust in horizontal direction
according to Δry and Δrz. And estimate circumrotation in
direction Y (the difference of thickness between the front
and back shims) as well as the circumrotation in direction
X (the difference of thickness between the left and right
shims) by Δa. Adjust the motor to meet the standard.
 Lubrication

In inspection of the lubrication or in the use of

lubrication, replace the lubricant whenever any of
the following conditions are found:
 Rubber-like deterioration
 Impurity
 Metal powder and badly discoloring
 Emulsification 乳化
 Separation of mineral oil and saponification base
皂化基

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 Lubrication
 Oil sample test -tools

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 Lubrication
 Oil sample test- procedure

1. install the 2. Put the 3. Draw the

bottle to the pipe into the sample oil
pump pump into bottle

5. Put the label on the bottle

and record the information
such as: date, location...

4. uninstall the
bottle and close the
cover of bottle www.zpmc.com
 Lubrication

 For all the reducers of the three cranes ,after

[ 300 ] hours of first running the lubrication oil
shall be replaced first time , then every [ 5000 ]
hours or [ 2 ] years the lubrication oil shall be
replaced.
 For the hydraulic system: we should clean valves
every [ 5 ] years, clean cylinders every [ 8 ]
years, clean the filter every [ 3 ] months, clean
the oil tank every [ 3 ] years; we should change
the hydraulic oil after [ 500~ 700 ] hours of first
operation, then change oil every [ 3000~5000 ]
hours .
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 Lubrication
Lubrication Proposed Lubrication
No. Part Name Interval
Type Material
1 wire rope monthly coating lithium based grease
check oil lever daily, oil
2 main hoist reducer oil pool L-CKC 320
as need
check oil lever daily, oil
3 trolley drive reducer oil pool L-CKC 320
as need
check oil lever daily, oil
4 boom hoist reducer oil pool L-CKC 220
as need
check oil lever daily, oil
5 gantry reducer (twin 40’) oil pool L-CKC 220
as need
check oil lever daily, oil
6 gantry reducer (61t & 45t) oil pool L-CKC 220
as need

7 emergency device oil as need oil pool L-CKC 220

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 Lubrication Points

 STS refer to the drawing J575A7204

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 Inspection
 Inspection of abnormal temperature rise, noise, vibration.

 Abnormal temperature may caused by:

1. Improper lubrication
2. Improper gear meshing
3. Bearing clearance is too loose or too tight (or bearing damage)
4. Brake not fully released or not centered (one side released but the
other side still touching the disc)
5. Hydraulic thruster’s oil internal leakage
6. Abnormal operation of the relief valve

 Abnormal noise may caused by improper gear meshing, bearing damage,

loose bearing clearances, shaft bending, loose bolts, interference or motor fan
damage, lack of lubrication.
 The abnormal vibration may caused by improper gear meshing and lack of
adequate rigidity of the installation base ,which can be found during test
running.

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Inspection

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 Inspection
Inspection items Measuring Method Maintenance tolerance

Span (S) Measured by a steel ≤ ± 3mm

ruler
Difference in height Measured by a transit or ≤±10mm
level

Lateral Straightness Measure by a transit ≤1 mm

Difference between Measured by a steel σ≤ ± 2mm

boom and girder rail ruler

Center distance Measured by a steel 0≤σ≤0.5mm

between boom and ruler
girder rail
 Inspection

Rail clip devices:

 Loosening of the bolts
 Breakage of bolts, studs, or weld fillets
 Elongation of holes
 Rotation of clips
Rail:
 Excessive wear or flattening of the rail head
 Wear of edges of rail head
 Rail breakage
 Deformation at joints caused by wheels running over
gaps

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 Inspection
Wear Limitation of Gantry Wheel 65T-55M STS

Wear Limitation
Original
dimension Driving wheel Driven wheel

625 or the difference of the

625 or the difference of the 2 driven wheel
2 driving wheel diameter is
D 650 D’ diameter is more than 3.25mm （ 0.5%
more than 1.3mm （ 0.2%
D）
D）
h 25 h’ 35
b 127 b’ 145
a 26.5 a’ 17.5
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 Inspection
Wear Limitation of Gantry Wheel 65T-64M STS

Wear Limitation
Original
dimension Driving wheel Driven wheel

770 or the difference of the 2

770 or the difference of the 2 driven wheel
D 800 D’ driving wheel diameter is more
diameter is more than 4mm （ 0.5%D ）
than 1.6mm （ 0.2% D ）
h 25 h’ 35
b 147 b’ 165
a 26.5 a’ 17.5

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Inspection
Wear Limitation of trolley Wheel

（ these dimension are applicable at any place in tread ）

Original
Wear Limitation
dimension
D 615 or the difference of the 2 wheel diameter is
D 630
’ more than 3.15mm （ 0.5%D ）

h 25 h’ 32.5

a 30 a’ 22.5

b 100 b’ 115

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Inspection

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 Inspection
When find the following situation, repair or
change the cargo hook.
 Any bending or twisting by 10.
 Any distortion by 15% in throat
opening.
 Any wear exceeding 10% of the
original section dimension of the hook
or load pin.
 Any latch that does not close the
hook’s throat.
 If no dimension is reduced by more
than 10%, repair of cracks, nicks and
gouges shall be carried out by
designated person by grinding
longitudinally.
 Deform or crack on the screw segment
of the tail of the hook.

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 Inspection
When find the following
situation, repair or change the
twist lock pin.
 Crack on the face of the head of
twist lock pin, shaft and the
connect root of the lock head;
 Damage or wear of the twist
lock pin’s head;
 Deform or crack on the screw
segment of the tail.

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 Inspection
Standards for Brake Disk Changing

Main Trolley Boom Boom hoist Main hoist

hoist drive hoist emergency brake emergency brake

Brake disc thickness 30 30 30 40 40

Wear limitation 27 27 27 36 36

Convex or concave
2 2 2 3 3
on the disc surface

Wear thickness should not more than 40% of base thickness.

Brake lining wear
Interface between brake lining and brake disk should not less than
limit
75%. The brake lining with adjust face or aging should be replaced.

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 Inspection
Contents of Preventive Action
Inspection Items Inspection
Gear Grease on gear Apply grease if poorly greased.
Gear coupling Alignment Realign if out of tolerance
Gear engagement Adjust the attachment if engagement is not proper.
and wear Replace excessive wear ones
Sliding surface of Lubricating Lubricate the respective lubrication points as required.
bearing, sheaves, condition
wheel, pins, lever
Wear condition Replace if wear is excessive
pins, etc.
Bolts, nuts, keys, Looseness, Tighten sufficiently.
pins, shaft Attachment Replace if quality is deteriorated
coupling bolts condition of split pin
retainer
Gear box Lubrication Add oil if the amount of oil is few.
Temperature Replace if quality is deteriorated.
sound Check abnormal sound
Wire ropes Lubricating Apply grease as necessary if grease is insufficient or degraded.
condition, broken Inspect the wire rope.
wires,
abrasion
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 Inspection
Wire rope end termination Condition of wire end Tighten loose bolts with specified torque.

High strength bolts, and Looseness Replace if loose.

welding for steel Crack, damage Repair if crack or damage is observed.
structure
Brake lining Wear, fitness to brake disc Replace if wear is excessive.
Brake disc Wear of sliding surface Repair if sliding surface is worn or rough.
rail and rail clip Bolt looseness, Tighten loose bolts with specified torque,
Rail abrasion, Replace excessive wear ones,
Rail distortion Realign
Hook, headblock, lock pin Abrasion, Replace excessive abrasion ones or ones with
in the spreader crack crack
Sheave, drum, idler Abrasion Replace if wear is excessive
Other consumable parts Abrasion, Replace if wear is excessive,
(such as seal, bulb ） damage Repair or replace damaged
Steel structure Crack, paint, etc. Refer to Steel structure maintenance manual
Safety device Any abnormity Repair while there is abnormity.

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