Escolar Documentos
Profissional Documentos
Cultura Documentos
1. Gearbox oil
- Inspect oil level and oil condition Gearbox #1 Good( ) / Not Good( )
Note : Fill up where applicable Gearbox #2 Good( ) / Not Good( )
3. Bearing
- Inspect abnormal sound Gearbox #1 Good( ) / Not Good( )
Note : Fill up where applicable Gearbox #2 Good( ) / Not Good( )
3. Visual check
- Check coupling motor & gear box (Bush Coupling) Motor #1 Good( ) / Not Good( )
- Check terminations Motor #2 Good( ) / Not Good( )
- Check mounting bolts and frame Motor #3 Good( ) / Not Good( )
Note : Fill up where applicable Motor #4 Good( ) / Not Good( )
5. Emergency Motor
- Check coupling condition & chain link Motor #1 Good( ) / Not Good( )
- Check limit switch working condition Motor #2 Good( ) / Not Good( )
1. Visual check
- Check broken strands, deformation and kinks Drum Good( ) / Not Good( )
- Diameter (NOELL/ZPMC-A : 26.2mm~28.0mm) Backreach Good( ) / Not Good( )
- Diameter (IMPSA : 26.7mm~28.5mm) Trolley platform Good( ) / Not Good( )
- Diameter (MITSUI : 26.2mm~23.3mm) Headblock Good( ) / Not Good( )
- Diameter (ZPMC-C : 32.00mm~29.76mm)
- Broken strands (<18 wires)
Note : Fill up where applicable
2. Check bearing any abnormal noise All drums Good( ) / Not Good( )
General Remark :
Document No. #REF!
Revision No. #REF!
Effective Date #REF!
SUPPORTING DOCUMENT Page 6 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 5 of 8
1. Check groove condition any damaged or rope trace mark Backreach Good( ) / Not Good( )
Note : Fill up where applicable Trolley platform Good( ) / Not Good( )
Headblock Good( ) / Not Good( )
Boom tip Good( ) / Not Good( )
4. Structure
- Check bolt tightness and condition All couplings Good( ) / Not Good( )
General Remark :
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Effective Date #REF!
SUPPORTING DOCUMENT Page 7 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 6 of 8
1. Cable termination
- Check cable damage and breakage at cable lugs Main hoist drum Good( ) / Not Good( )
4. Check 3-way gear condition Main hoist drum Good( ) / Not Good( )
Note : Fill up where applicable
6. Driven pulley
- Check pulley mounting, side guide, wear and crack Main hoist drum Good( ) / Not Good( )
Note : Fill up where applicable
1. Cable / conduit
- Check cable condition, insulation and cable lug Trolley platform / trolley house Good( ) / Not Good( )
2. Limit switch
- Check positioning, rusty, functionality and mounting Trolley platform / trolley house Good( ) / Not Good( )
3. Counter weight
- Check condition Trolley platform / trolley house Good( ) / Not Good( )
Note : Fill up where applicable
4. Striker
- Check condition Spreader cable / headblock Good( ) / Not Good( )
Note : Fill up where applicable
General Remark :
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Revision No. #REF!
Effective Date #REF!
SUPPORTING DOCUMENT Page 8 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 7 of 8
1. Coupling
- Check mounting, rusty, alignment and sprider wear Main hoist motor and drum Good( ) / Not Good( )
Note : Fill up where applicable
3. Driven pulley
- Check pulley mounting, side guide, wear and crack Main hoist drum Good( ) / Not Good( )
Note : Fill up where applicable
4. Electrical
- Check cable connection Main hoist drum Good( ) / Not Good( )
1. Cable termination
- Check cable damage and breakage at cable lugs Main hoist drum Good( ) / Not Good( )
2. Coupling tightness
- Check bolt tightness All couplings Good( ) / Not Good( )
3. Check 3-way gear condition Main hoist drum Good( ) / Not Good( )
Note : Fill up where applicable
1. Spreader drum
- Check drum condition Trolley platform / trolley house Good( ) / Not Good( )
- Check cable condition Good( ) / Not Good( )
4. Electrical
- Check cable connection and slip ring carbon brushes Trolley platform / trolley house Good( ) / Not Good( )
- Check short length cable and junction box Headblock Good( ) / Not Good( )
Document No. #REF!
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SUPPORTING DOCUMENT Page 9 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 8 of 8
5. Limit switch
- Check limit switch condition Trolley platform / trolley house Good( ) / Not Good( )
6. Absorber
- Check condition Headblock Good( ) / Not Good( )
1. Twistlock
- Check gap, lock pin and condition All twistlocks Good( ) / Not Good( )
2. Electrical
- Check limit switch and functionality Headblock lock/unlock lever Good( ) / Not Good( )
3. Structure
- Check condition, ladder, hand rail and grating Good( ) / Not Good( )
1. Power pack
- Check oil level, condition and cleanliness
- Check working pressure (160±10 psi) Backreach / TLS platform / trolley house Good( ) / Not Good( )
- Check hose, valve and piping Pressure : _________ psi Good( ) / Not Good( )
2. Hydraulic cylinder
- Check oil leak, guide roller and condition Backreach / TLS platform / trolley house Good( ) / Not Good( )
3. Positioner sensor
- Check wire string, mounting and crack All cylinders Good( ) / Not Good( )
General Remark :
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Revision No. #REF!
Effective Date #REF!
SUPPORTING DOCUMENT Page 10 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 1 of 8
1. Reserve stroke height (10 mm) Brake #1 (Height : _________ mm) Good( ) / Not Good( )
- Inspect stroke indicator setting and manual release Brake #2 (Height : _________ mm) Good( ) / Not Good( )
Note : Fill up where applicable Brake #3 (Height : _________ mm) Good( ) / Not Good( )
Brake #4 (Height : _________ mm) Good( ) / Not Good( )
3. Air gap
- Check any rubbing All brakes Good( ) / Not Good( )
4. Brake pad and disc Brake #1 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
- Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm) Brake #1 LHS : ______mm Good( ) / Not Good( )
ZPMC-C: Disk wear >20% from 30mm, Pad >3mm Brake #2 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
ZPMC(Pad : ≥ 3 mm, Disc : ≤ 1.0mm wear on each side) Brake #2 LHS : ______mm Good( ) / Not Good( )
- Check and clean disc surface Brake #3 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
Note : Fill up where applicable Brake #3 LHS : ______mm Good( ) / Not Good( )
Brake #4 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
Brake #4 LHS : ______mm Good( ) / Not Good( )
8. Structure
- Check pivot pin, linkage and mounting Good( ) / Not Good( )
General Remark :
Document No. #REF!
Revision No. #REF!
Effective Date #REF!
SUPPORTING DOCUMENT Page 11 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 2 of 8
3. Visual check
- Check armature winding for burn marks, scratches Motor #1 Good( ) / Not Good( )
and damages (For DC motor only) Motor #2 Good( ) / Not Good( )
- Check structure and wire termination Motor #3 Good( ) / Not Good( )
Note : Fill up where applicable Motor #4 Good( ) / Not Good( )
4. Check motor in running condition for sparks Motor #1 Good( ) / Not Good( )
Note : For DC motor only Motor #2 Good( ) / Not Good( )
5. Emergency motor
- Check coupling condition Motor #1 Good( ) / Not Good( )
- Check limit switch working condition Motor #2 Good( ) / Not Good( )
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SUPPORTING DOCUMENT Page 12 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 3 of 8
6. Carbon brush and holder Motor #1 - Top (3 pcs) Good( ) / Not Good( )
- Check length and condition Motor #1 - Bottom (3 pcs) Good( ) / Not Good( )
Note : For DC motor only Motor #1 - Right (3 pcs) Good( ) / Not Good( )
Motor #1 - Left (3 pcs) Good( ) / Not Good( )
Motor #2 - Top (3 pcs) Good( ) / Not Good( )
Motor #2 - Bottom (3 pcs) Good( ) / Not Good( )
Motor #2 - Right (3 pcs) Good( ) / Not Good( )
Motor #2 - Left (3 pcs) Good( ) / Not Good( )
1. Visual check
- Check broken strands, deformation and kinks Drum Good( ) / Not Good( )
- Diameter (2 6.2mm~mm) Backreach Good( ) / Not Good( )
- Broken strands (<18 wires) Trolley platform Good( ) / Not Good( )
Note : Fill up where applicable Boom tip Good( ) / Not Good( )
2. Check bearing any abnormal noise All drums Good( ) / Not Good( )
General Remark :
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Revision No. #REF!
Effective Date #REF!
SUPPORTING DOCUMENT Page 13 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 4 of 8
1. Check groove condition any damaged or rope trace mark Backreach Good( ) / Not Good( )
Note : Fill up where applicable Trolley platform Good( ) / Not Good( )
Boom tip Good( ) / Not Good( )
4. Structure
- Check bolt tightness and condition All couplings Good( ) / Not Good( )
2. Limit switch
- Check condtion, mounting and functionality All limit switches Good( ) / Not Good( )
3. Flag sensor
- Check condtion, mounting and functionality All flag sensors Good( ) / Not Good( )
1. Coupling
- Check mounting, rusty, alignment and sprider wear Trolley motor Good( ) / Not Good( )
Note : Fill up where applicable
2. Electrical
- Check cable connection Trolley motor Good( ) / Not Good( )
3. Structure
- Check mounting, wheel and bearing condition Trolley LS LHS Good( ) / Not Good( )
Note : Fill up where applicable
4. Encoder sensor
- Check sensor surface and condition Trolley motor Good( ) / Not Good( )
1. Wheel bearings
- Check abnormal noise All location Good( ) / Not Good( )
2. Trolley wheel
- Check any crack or damage on wheel flange All wheels Good( ) / Not Good( )
- Check wheel bracket bolts tighten All wheel brackets Good( ) / Not Good( )
- Check wheel cover bolt tightness All bolts Good( ) / Not Good( )
Note : Fill up where applicable
6. Structure
- Check catenary structure condition 1. Catenary LHS Good( ) / Not Good( )
Note : Fill up where applicable 2. Catenary RHS Good( ) / Not Good( )
7. Guide roller
- Check guide roller tighness and condition All location Good( ) / Not Good( )
8. Support roller
- Check support roller, bearing and shaft condition All location Good( ) / Not Good( )
1. Cylinder
- Check abnormal sound and cylinder condition
- Check hose and any leakage All cylinders Good( ) / Not Good( )
Note : Fill up where applicable
2. Cross joint
- Check vibration and any abnormal sound All location Good( ) / Not Good( )
- Check bearing and shaft condition All location Good( ) / Not Good( )
3. Sheave
- Check bolt tighness, sheave and bearing condition All location Good( ) / Not Good( )
4. Limit switch
- Check limit switch condition and functionality All limit switches Good( ) / Not Good( )
General Remark :
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Revision No. #REF!
Effective Date #REF!
SUPPORTING DOCUMENT Page 17 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 8 of 8
1. Festoon rail
- Check deformation, dents and leveling condition Along rails Good( ) / Not Good( )
2. Festoon cable
- Check cable and cable clamp mouting condition All cables Good( ) / Not Good( )
4. Festoon bumper
- Check mounting and bumber condition All bumpers Good( ) / Not Good( )
6. Belting system
- Check belting, pulley and bearing condition Motor #1 and #2 Good( ) / Not Good( )
Note : Fill up where applicable
9. Festoon carrier
- Check carrier condition All carrier Good( ) / Not Good( )
General Remark :
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Effective Date #REF!
SUPPORTING DOCUMENT Page 18 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 1 of 4
1. Gantry brake
- Check wire termination
- Check friction disc, stationary disc and coil assembly All brakes Good( ) / Not Good( )
- Check mounting cover and silicon seal condition
Note : Fill up where applicable
Seaside
Height : #1 : ______ mm #5 : ______ mm) Good( ) / Not Good( )
Height : #2 : ______ mm #6 : ______ mm) Good( ) / Not Good( )
Height : #3 : ______ mm #7 : ______ mm) Good( ) / Not Good( )
Height : #4 : ______ mm #8 : ______ mm) Good( ) / Not Good( )
3. Braking torque
Lanside
- Inspect setting and mechanical component Torque : #1 : ______ Nm #5 : ______ Nm) Good( ) / Not Good( )
Note : Fill up where applicable Torque : #2 : ______ Nm #6 : ______ Nm) Good( ) / Not Good( )
IMPSA-B : > 207Nm, ZPMC-B : >320Nm, ZPMC-C : 350Nm Torque : #3 : ______ Nm #7 : ______ Nm) Good( ) / Not Good( )
Torque : #4 : ______ Nm #8 : ______ Nm) Good( ) / Not Good( )
Seaside
Torque : #1 : ______ Nm #5 : ______ Nm) Good( ) / Not Good( )
Torque : #2 : ______ Nm #6 : ______ Nm) Good( ) / Not Good( )
Torque : #3 : ______ Nm #7 : ______ Nm) Good( ) / Not Good( )
Torque : #4 : ______ Nm #8 : ______ Nm) Good( ) / Not Good( )
4. Air gap
- Check any rubbing All brakes Good( ) / Not Good( )
Note : Fill up where applicable
6. Brake pad and disc (Seaside) Brake #1 RHS : _____mm, LHS _____mm Good( ) / Not Good( )
- Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm) Disc : _____mm Good( ) / Not Good( )
- Check and clean disc surface
Note : Fill up where applicable Brake #2 RHS : _____mm, LHS _____mm Good( ) / Not Good( )
Disc : _____mm Good( ) / Not Good( )
8. Servolifter / Thruster
- Inspect oil, electrical and mechanical part All servolifters Good( ) / Not Good( )
Note : Fill up where applicable
1. Gearbox oil
- Inspect oil level and oil condition All gearboxes Good( ) / Not Good( )
2. Structure
- Inspect mounting bolts tightness and crack All gearboxes Good( ) / Not Good( )
Note : Fill up where applicable
3. Bearing
- Inspect abnormal sound All gearboxes Good( ) / Not Good( )
Note : Fill up where applicable
5. Coupling
- Check rubber insert for coupling condition
- Check circlips condition All couplings Good( ) / Not Good( )
Note : Fill up where applicable
6. Housekeeping All location Done( ) / Not Done( )
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Effective Date #REF!
SUPPORTING DOCUMENT Page 20 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 3 of 4
1. Sound inspection
- Check any abnormal sound All motors Good( ) / Not Good( )
2. Electrical
- Check wire termination at motor termination box All motors Good( ) / Not Good( )
3. Structure
- Check cover, mounting and body codition All motors Good( ) / Not Good( )
3. Limit switch
- Check condition and functionality All location Good( ) / Not Good( )
- Check leakage and mounting condition
4. Structure
- Check any leakage and cylinder condition
- Check brake shoe / lining condition All location Good( ) / Not Good( )
- Check mounting condition
Note : Fill up where applicable
2. Wire rope
- Check wire rope rusty and stringness Right and left side of boom girder Good( ) / Not Good( )
Note : Fill up where applicable
1. Siren
- Check siren functionality and condition All sirens Good( ) / Not Good( )
- Check wire termination condition
2. Warning light
- Check bulb and motor condition
- Check lamp cover and mounting condition All warning lights Good( ) / Not Good( )
- Check wire termination condition
1. Wheel
- Check wheel bearing condition and abnormal sound All wheels Good( ) / Not Good( )
2. Structure
- Check wheel flange cracks or damages and condition All wheels Good( ) / Not Good( )
- Check mounting condition
General Remark :
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Revision No. #REF!
Effective Date #REF!
SUPPORTING DOCUMENT Page 22 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 1 of 5
1. Reserve stroke height (10 mm) Brake #1 (Height : _________ mm) Good( ) / Not Good( )
- Inspect stroke indicator setting and manual release
2. Braking torque
- Inspect setting and mechanical component Brake #1 (Torque : ________________ Nm) Good( ) / Not Good( )
Note : IMPSA-A : ≥ 1890Nm, NOELL/MITSUI/ZPMC-A: ≥ 14850 Nm,
IMPSA-B : >7200Nm, ZPMC-B : >5940Nm, ZPMC-C: >6000Nm
3. Air gap
- Check any rubbing Service brake Good( ) / Not Good( )
4. Brake pad and disc Brake pad RHS : ________mm Good( ) / Not Good( )
- Check and clean disc surface Brake pad LHS : ________mm Good( ) / Not Good( )
- Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm) Brake disc : ________mm Good( ) / Not Good( )
ZPMC (Pad : >3.0 mm, Disc : >1.0mm wear on each side)
6. Check wedge and shackle kit Service brake Good( ) / Not Good( )
7. Servolifter / Thruster
- Inspect oil, electrical and mechanical part Service brake Good( ) / Not Good( )
8. Structure
- Check pivot pin, linkage and mounting Good( ) / Not Good( )
4. Brake pad and disc Brake #1 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
- Inspect pad and disc (Pad : ≥ 8 mm, Disc : ≥ 28 mm) Brake #1 LHS : ______mm Good( ) / Not Good( )
- Check and clean disc surface Brake #2 RHS : ______mm Good( ) / Not Good( )
Note : Fill up where applicable Brake #2 LHS : ______mm Good( ) / Not Good( )
1. Gearbox oil
- Inspect oil level and oil condition Gearbox #1 Good( ) / Not Good( )
2. Structure
- Inspect mounting bolts tightness and crack Gearbox #1 Good( ) / Not Good( )
3. Bearing
- Inspect abnormal sound Gearbox #1 Good( ) / Not Good( )
2. Visual check
- Check structure and wire termination Boom motor Good( ) / Not Good( )
3. Emergency Motor
- Check coupling condition Boom emergency motor Good( ) / Not Good( )
- Check limit switch working condition
1. Visual check
- Check broken strands, deformation and kinks Wire rope drum Good( ) / Not Good( )
- Broken strands (<18 wires) Boom tip Good( ) / Not Good( )
- Diameter : IMPSA-A : >28.8mm, IMPSA-B : >34.2mm, A-Frame Good( ) / Not Good( )
ZPMC-A/C : 36mm~33.4mm, ZPMC-B : 32.4mm
NOELL/MITSUI : 30mm~2 7.9mm
4. Support plate
- Check condition All plates Good( ) / Not Good( )
2. Check bearing any abnormal noise All drums Good( ) / Not Good( )
1. Check groove condition any damaged or rope trace mark Boom tip Good( ) / Not Good( )
A-Frame Good( ) / Not Good( )
2. Check locking / keeper plate condition Boom tip Good( ) / Not Good( )
A-Frame Good( ) / Not Good( )
General Remark :
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Revision No. #REF!
Effective Date #REF!
SUPPORTING DOCUMENT Page 25 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 4 of 5
1. Cable / conduit
- Check cable condition, insulation and cable lug A-Frame Good( ) / Not Good( )
2. Limit switch
- Check positioning, rusty, functionality and mounting A-Frame Good( ) / Not Good( )
3. Striker
- Check condition A-Frame Good( ) / Not Good( )
1. Cable termination
- Check cable damage and breakage at cable lugs Boom drum Good( ) / Not Good( )
6. Driven pulley
- Check pulley mounting, side guide, wear and crack Boom drum Good( ) / Not Good( )
Note : Fill up where applicable
General Remark :
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Revision No. #REF!
Effective Date #REF!
SUPPORTING DOCUMENT Page 26 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 5 of 5
1. Servolifter
- Check oil condition and any leakage
- Check linkage split-pin and conduit condition A-Frame Good( ) / Not Good( )
- Check rubber bumper
Note : Fill up where applicable
2. Limit Switch
- Check condition and functionality All limit switches Good( ) / Not Good( )
Note : Fill up where applicable
4. Power pack
- Check oil condition and any leakage A-Frame Good( ) / Not Good( )
Note : Fill up where applicable
5. Plunger
- Check plunger and spring condition A-Frame Good( ) / Not Good( )
Note : Fill up where applicable
General Remark :
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Effective Date #REF!
SUPPORTING DOCUMENT Page 27 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 1 of 3
4. Backreach
- Check functionality and condition Backreach Good( ) / Not Good( )
- Check wire termination Multi-functional platform Good( ) / Not Good( )
Note : Fill up where applicable
5. Portal beam
- Check functionality and condition Right hand side Good( ) / Not Good( )
- Check wire termination Left hand side Good( ) / Not Good( )
Note : Fill up where applicable
4. Indicator light
- Check functionality and condition All location Good( ) / Not Good( )
- Check wire termination
6. Foot siren
- Check functionality and condition Siren Good( ) / Not Good( )
- Check wire termination
9. Operator seat
- Check functionality and condition Operator seat Good( ) / Not Good( )
1. Compressor
- Check structure and condition Control room Good( ) / Not Good( )
- Check wire termination and functionality Operator cabin Good( ) / Not Good( )
- Check gas quantity and any leakage Checker cabin Good( ) / Not Good( )
Note : Fill up where applicable
2. Indoor unit
- Check structure and condition Control room Good( ) / Not Good( )
- Check wire termination and functionality Operator cabin Good( ) / Not Good( )
Note : Fill up where applicable Checker cabin Good( ) / Not Good( )
4. Mechanical part
- Check blower motor mounting condition All location Good( ) / Not Good( )
- Check belting condition
- Check cleanliness
General Remark :
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Effective Date #REF!
SUPPORTING DOCUMENT Page 30 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
1. Trolley system
- Pump-in new grease into greasing point Trolley sheave Done( ) / Not Done( )
Note : Fill up where applicable Trolley floating shaft Done( ) / Not Done( )
Trolley plumber block Done( ) / Not Done( )
Catenary wheel Done( ) / Not Done( )
Catenary sheave Done( ) / Not Done( )
Catenary McGill guide roller Done( ) / Not Done( )
Backreach-catenary sheave Done( ) / Not Done( )
Backreach rope tensioner bearing Done( ) / Not Done( )
1. Boom system
- Pump-in new grease into greasing point Boom drum Done( ) / Not Done( )
Note : Fill up where applicable
General Remark :
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Effective Date #REF!
SUPPORTING DOCUMENT Page 31 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 1 of 3
1. Guide rail
- Check buffer spring and rail condition All location Good( ) / Not Good( )
- Check mounting condition
2. Gear
- Check rack and pinion gear condition All location Good( ) / Not Good( )
4. Motor
- Check casing and mounting condition Top of cabin Good( ) / Not Good( )
5. Brake
- Check functionality and brake condition All brakes Good( ) / Not Good( )
6. Cabin level
- Check setting on each floor level All floors Good( ) / Not Good( )
7. Push button
- Check functionality and condition All push buttons Good( ) / Not Good( )
8. Cable
- Check cable insulation and condition Power cable Good( ) / Not Good( )
- Check protection rubber and mounting condition
9. Carrier structure
- Check door and roof door condition Carrier Good( ) / Not Good( )
- Check ladder condition
10. Intercomm
- Check condition and functionality Inside carrier Good( ) / Not Good( )
1. Electrical part
- Check AC power LED light up Machinery house
- Determine standby battery condition ( 25.5 ≤ x ≤ 26.6 Vdc ) - Zone 1 Good( ) / Not Good( )
- Check any alarm LED light up from panel - Zone 2 Good( ) / Not Good( )
- Fire, Fault, Off, Extinguisher release, Walk test, External - Zone 3 Good( ) / Not Good( )
acoustic alarm off, CPU fault, Power supply fault. - Zone 4 Good( ) / Not Good( )
- Any fault message on the display (Stated the fault message) - Main Good( ) / Not Good( )
Note : Fill up where applicable - Charger Good( ) / Not Good( )
- Evacuate Good( ) / Not Good( )
2. Mechanical Part
- Visual Check for cylinder pressure gauge reading
(±170 bar for 225 bar system) Good( ) / Not Good( )
- Examine cylinder valve and hoses for sign of damage,
wear or leakage Good( ) / Not Good( )
- Inspect all piping & nozzles for any sign damage & leakage Good( ) / Not Good( )
Note : Fill up where applicable
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SUPPORTING DOCUMENT Page 32 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 2 of 3
2. Control console
- Check functionality and condition Machinery house Good( ) / Not Good( )
- Check structure
3. Structure
- Check structure condition Rubber buffer Good( ) / Not Good( )
- Check hook and latch condition Hook block Good( ) / Not Good( )
5. Electrical part
- Check wire termination and contactor condition Electrical box Good( ) / Not Good( )
1. Compressor
- Check oil level sufficient, air filter, V-belt, pressure gauge, Machinery house Good( ) / Not Good( )
safety valve, piping and mounting condition
- Check any abnormal sound or vibration
2. Pressure Switch
- Check pressure setting Machinery house Good( ) / Not Good( )
Note : Cut in: 9.9 kg/cm2 & Cut out: 8.0 kg/cm2
- Adjusting screw locknut and check wire termination
3. Motor
- Check mounting and any abnormal sound Machinery house Good( ) / Not Good( )
General Remark :
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SUPPORTING DOCUMENT Page 33 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 3 of 3
2. Check lighting condition and functionality Cabin ceiling Good( ) / Not Good( )
3. Intercomm
- Check condition and functionality Good( ) / Not Good( )
4. Structure
- Check mounting and condition All location Good( ) / Not Good( )
- Check door and glass
General Remark :
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SUPPORTING DOCUMENT Page 34 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM: Page 1 of 1
1. Bushing
- Check abnormal sound and vibration All location Good( ) / Not Good( )
3. Rest support
- Check forestay rest support condition All supports Good( ) / Not Good( )
4. Boom buffer
- Check condition and mounting A-Frame Good( ) / Not Good( )
3. Structure
- Check mounting and condition All sheaves Good( ) / Not Good( )
1. Indicator bulb
- Check condition and functionality All indicators bulbs Good( ) / Not Good( )
2. Check lighting condition and functionality Cabin ceiling Good( ) / Not Good( )
3. Structure
- Check mounting and condition All location Good( ) / Not Good( )
- Check door and glass
4. Intercomm
- Check condition and functionality Good( ) / Not Good( )
General Remark :
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Effective Date #REF!
SUPPORTING DOCUMENT Page 35 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
1. Gantry system
- Pump-in new grease into greasing point All boggies Done( ) / Not Done( )
1. Boom system
- Pump-in new grease into greasing point All boom sheaves Done( ) / Not Done( )
1. Motor
- Check mounting and condition Main cable reel motor Good( ) / Not Good( )
2. Main cable
- Check cable condition Main power cable Good( ) / Not Good( )
3. Structure
- Check mounting and condition All mounting Good( ) / Not Good( )
4. Slip ring
- Check slip rings condition Good( ) / Not Good( )
5. Gearbox
- Check gearbox oil condition Good( ) / Not Good( )
- Check mounting and condition Good( ) / Not Good( )
- Check any abnormal sound Good( ) / Not Good( )
General Remark :
Document No. #REF!
Revision No. #REF!
Effective Date #REF!
SUPPORTING DOCUMENT Page 37 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
1. Boom backstay
- Pump-in new grease into greasing point All greasing points Done( ) / Not Done( )
Note : Fill up where applicable
1. KBT coupling
- Pump-in new grease into greasing point Done( ) / Not Done( )
Note : Fill up where applicable
Please see attachment (No. : )
General Remark :
Document No. #REF!
Revision No. #REF!
Effective Date #REF!
SUPPORTING DOCUMENT Page 38 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AC/DC MEGGER : Page 1 of 1
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 1 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
QUAY CRANE
PREVENTIVE MAINTENANCE CHECKLIST
MONTH / YEAR :
CRANE NUMBER :
JOB NUMBER :
W.O. NUMBER :
DATE/TIME END :
CRANE :
TROLLEY :
GANTRY :
BOOM :
PM CHECKLIST TYPE :
Please tick ( X ) where applicable :
MONTHLY PM : Page 1 to page 30 ( )
TROLLEY SYSTEM
Date :
GANTRY SYSTEM
Date :
BOOM SYSTEM
Date :
AUXIALLARY SYSTEM
Date :
GREASING
Date :
VERIFIED BY : SIGNATURE :
Date :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 2 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 1 of 8
1. Reserve stroke height (10 mm) Brake #1 (Height : _________ mm) Good( ) / Not Good( )
- Inspect stroke indicator setting and manual release Brake #2 (Height : _________ mm) Good( ) / Not Good( )
Note : Fill up where applicable Brake #3 (Height : _________ mm) Good( ) / Not Good( )
Brake #4 (Height : _________ mm) Good( ) / Not Good( )
2. Braking torque
Brake #1 (Torque : ________________ Nm) Good( ) / Not Good( )
- Inspect setting and mechanical component Brake #2 (Torque : ________________ Nm) Good( ) / Not Good( )
Note : IMPSA-A :≥ 15.75kNm, NOELL/MITSUI : ≥ 14.85kNm, Brake #3 (Torque : ________________ Nm) Good( ) / Not Good( )
IMPSA-B : 27kNm, ZPMC-A : 12.6kNm Brake #4 (Torque : ________________ Nm) Good( ) / Not Good( )
ZPMC-A : ≥ 14.85kNm, ZPMC-C : 19kNm
3. Air gap
- Check any rubbing All brakes Good( ) / Not Good( )
4. Brake pad and disc Brake #1 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
- Inspect pad and disc Brake #1 LHS : ______mm Good( ) / Not Good( )
- Check and clean disc surface Brake #2 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
Note : Fill up where applicable Brake #2 LHS : ______mm Good( ) / Not Good( )
All cranes (Pad : ≥ 5 mm, Disc : ≥ 27 mm) Brake #3 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
ZPMC-B (Pad : ≥ 3 mm, Disc :≤1.0mm wear) Brake #3 LHS : ______mm Good( ) / Not Good( )
ZPMC-C (Pad : > 3 mm, Disc wear more than 20%) Brake #4 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
Brake #4 LHS : ______mm Good( ) / Not Good( )
8. Structure
- Check pivot pin, linkage and mounting Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 3 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 2 of 8
3. Proximity sensor
- Check setting and functionality Good( ) / Not Good( )
Note : Fill up where applicable
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 4 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 3 of 8
1. Gearbox oil
- Inspect oil level and oil condition Gearbox #1 Good( ) / Not Good( )
Note : Fill up where applicable Gearbox #2 Good( ) / Not Good( )
2. Structure
- Inspect mounting bolts tightness and crack Gearbox #1 Good( ) / Not Good( )
Note : Fill up where applicable Gearbox #2 Good( ) / Not Good( )
3. Bearing
- Inspect abnormal sound Gearbox #1 Good( ) / Not Good( )
Note : Fill up where applicable Gearbox #2 Good( ) / Not Good( )
3. Visual check
- Check coupling motor & gear box (Bush Coupling) Motor #1 Good( ) / Not Good( )
- Check terminations Motor #2 Good( ) / Not Good( )
- Check mounting bolts and frame Motor #3 Good( ) / Not Good( )
Note : Fill up where applicable Motor #4 Good( ) / Not Good( )
5. Emergency Motor
- Check coupling condition & chain link Motor #1 Good( ) / Not Good( )
- Check limit switch working condition Motor #2 Good( ) / Not Good( )
1. Visual check
- Check broken strands, deformation and kinks Drum Good( ) / Not Good( )
- Diameter (NOELL/ZPMC-A : 26.2mm~28.0mm) Backreach Good( ) / Not Good( )
- Diameter (IMPSA : 26.7mm~28.5mm) Trolley platform Good( ) / Not Good( )
- Diameter (MITSUI : 26.2mm~23.3mm) Headblock Good( ) / Not Good( )
- Diameter (ZPMC-C : 32.00mm~29.76mm) Main Girder Area (5 mtr before Joint) Good( ) / Not Good( )
- Broken strands (<18 wires) Boom Girder Area (5 mtr after Joint) Good( ) / Not Good( )
Note : Fill up where applicable
2. Check bearing any abnormal noise All drums Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 6 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 5 of 8
1. Check groove condition any damaged or rope trace mark Backreach Good( ) / Not Good( )
Note : Fill up where applicable Trolley platform Good( ) / Not Good( )
Headblock Good( ) / Not Good( )
Boom tip Good( ) / Not Good( )
4. Structure
- Check bolt tightness and condition All couplings Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 7 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 6 of 8
1. Cable termination
- Check cable damage and breakage at cable lugs Main hoist drum Good( ) / Not Good( )
4. Check cam switch set Main hoist drum Good( ) / Not Good( )
- Check mounted bolt tightness
1. Cable / conduit
- Check cable condition, insulation and cable lug Trolley platform / trolley house Good( ) / Not Good( )
2. Limit switch
- Check positioning, rusty, functionality and mounting Trolley platform / trolley house Good( ) / Not Good( )
3. Counter weight
- Check condition Trolley platform / trolley house Good( ) / Not Good( )
Note : Fill up where applicable
4. Striker
- Check condition Spreader cable / headblock Good( ) / Not Good( )
Note : Fill up where applicable
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 8 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 7 of 8
1. Coupling
- Check mounting, rusty, alignment and sprider wear Main hoist motor and drum Good( ) / Not Good( )
Note : Fill up where applicable
3. Electrical Termination
- Check cable connection Main hoist drum Good( ) / Not Good( )
Note : Fill up where applicable
1. Cable termination
- Check cable damage and breakage at cable lugs Main hoist drum Good( ) / Not Good( )
2. Coupling tightness
- Check bolt tightness All couplings Good( ) / Not Good( )
3. Magnetic Clutch
- Check bearings condition Motor# 1 Good( ) / Not Good( )
- Check air gap Motor# 2 Good( ) / Not Good( )
Motor# 3 Good( ) / Not Good( )
Motor# 4 Good( ) / Not Good( )
4. Electrical
- Check cable connection and slip ring carbon brushes Trolley platform / trolley house Good( ) / Not Good( )
- Check short length cable and junction box Headblock Good( ) / Not Good( )
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 9 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 8 of 8
5. Limit switch
- Check limit switch condition Trolley platform / trolley house Good( ) / Not Good( )
6. Absorber
- Check condition Headblock Good( ) / Not Good( )
1. Twistlock
- Check gap, lock pin and condition All twistlocks Good( ) / Not Good( )
2. Switches
- Check headblock connected cond. Headblock lock/unlock lever Good( ) / Not Good( )
- Check headblock anchor sensor cond. Headblock lock/unlock lever Good( ) / Not Good( )
1. Power pack
- Check oil level, condition and cleanliness
- Check working pressure (160±10 psi) Backreach / TLS platform / trolley house Good( ) / Not Good( )
- Check hose, valve and piping Pressure : _________ psi Good( ) / Not Good( )
2. Hydraulic cylinder
- Check oil leak, guide roller and condition Backreach / TLS platform / trolley house Good( ) / Not Good( )
3. Positioner sensor
- Check wire string, mounting and crack All cylinders Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 10 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 1 of 8
1. Reserve stroke height (10 mm) Brake #1 (Height : _________ mm) Good( ) / Not Good( )
- Inspect stroke indicator setting and manual release Brake #2 (Height : _________ mm) Good( ) / Not Good( )
Note : Fill up where applicable Brake #3 (Height : _________ mm) Good( ) / Not Good( )
Brake #4 (Height : _________ mm) Good( ) / Not Good( )
2. Braking torque
Brake #1 (Torque : ________________ Nm) Good( ) / Not Good( )
- Inspect setting and mechanical component Brake #2 (Torque : ________________ Nm) Good( ) / Not Good( )
Note : IMPSA-A : ≥ 977Nm, NOELL /MITSUI/ZPMC-A : ≥ 1890Nm Brake #3 (Torque : ________________ Nm) Good( ) / Not Good( )
IMPSA-B : ≥ 977Nm, ZPMC-B : ≥ 5175 Nm, ZPMC-C : 5500Nm Brake #4 (Torque : ________________ Nm) Good( ) / Not Good( )
3. Air gap
- Check any rubbing All brakes Good( ) / Not Good( )
4. Brake pad and disc Brake #1 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
- Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm) Brake #1 LHS : ______mm Good( ) / Not Good( )
ZPMC-C: Disk wear >20% from 30mm, Pad >3mm Brake #2 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
ZPMC(Pad : ≥ 3 mm, Disc : ≤ 1.0mm wear on each side) Brake #2 LHS : ______mm Good( ) / Not Good( )
- Check and clean disc surface Brake #3 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
Note : Fill up where applicable Brake #3 LHS : ______mm Good( ) / Not Good( )
Brake #4 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
Brake #4 LHS : ______mm Good( ) / Not Good( )
8. Structure
- Check pivot pin, linkage and mounting Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 11 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 2 of 8
3. Visual check
- Check armature winding for burn marks, scratches Motor #1 Good( ) / Not Good( )
and damages (For DC motor only) Motor #2 Good( ) / Not Good( )
- Check structure and wire termination Motor #3 Good( ) / Not Good( )
Note : Fill up where applicable Motor #4 Good( ) / Not Good( )
4. Check motor in running condition for sparks Motor #1 Good( ) / Not Good( )
Note : For DC motor only Motor #2 Good( ) / Not Good( )
5. Emergency motor
- Check coupling condition Motor #1 Good( ) / Not Good( )
- Check limit switch working condition Motor #2 Good( ) / Not Good( )
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 12 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 3 of 8
6. Carbon brush and holder Motor #1 - Top (3 pcs) Good( ) / Not Good( )
- Check length and condition Motor #1 - Bottom (3 pcs) Good( ) / Not Good( )
Note : For DC motor only Motor #1 - Right (3 pcs) Good( ) / Not Good( )
Motor #1 - Left (3 pcs) Good( ) / Not Good( )
Motor #2 - Top (3 pcs) Good( ) / Not Good( )
Motor #2 - Bottom (3 pcs) Good( ) / Not Good( )
Motor #2 - Right (3 pcs) Good( ) / Not Good( )
Motor #2 - Left (3 pcs) Good( ) / Not Good( )
1. Visual check
- Check broken strands, deformation and kinks Drum Good( ) / Not Good( )
- Diameter (2 6.2mm~mm) Backreach Good( ) / Not Good( )
- Broken strands (<18 wires) Trolley platform Good( ) / Not Good( )
Note : Fill up where applicable Boom tip Good( ) / Not Good( )
2. Check bearing any abnormal noise All drums Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 13 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 4 of 8
1. Check groove condition any damaged or rope trace mark Backreach Good( ) / Not Good( )
Note : Fill up where applicable Trolley platform Good( ) / Not Good( )
Boom tip Good( ) / Not Good( )
4. Structure
- Check bolt tightness and condition All couplings Good( ) / Not Good( )
2. Limit switch
- Check condtion, mounting and functionality All limit switches Good( ) / Not Good( )
3. Flag sensor
- Check condtion, mounting and functionality All flag sensors Good( ) / Not Good( )
1. Coupling
- Check mounting, rusty, alignment and sprider wear Trolley motor Good( ) / Not Good( )
Note : Fill up where applicable
2. Electrical
- Check cable connection Trolley motor Good( ) / Not Good( )
3. Structure
- Check mounting, wheel and bearing condition Trolley LS LHS Good( ) / Not Good( )
Note : Fill up where applicable
4. Encoder sensor
- Check sensor surface and condition Trolley motor Good( ) / Not Good( )
1. Wheel bearings
- Check abnormal noise All location Good( ) / Not Good( )
2. Trolley wheel
- Check any crack or damage on wheel flange All wheels Good( ) / Not Good( )
- Check wheel bracket bolts tighten All wheel brackets Good( ) / Not Good( )
- Check wheel cover bolt tightness All bolts Good( ) / Not Good( )
Note : Fill up where applicable
6. Structure
- Check catenary structure condition 1. Catenary LHS Good( ) / Not Good( )
Note : Fill up where applicable 2. Catenary RHS Good( ) / Not Good( )
7. Guide roller
- Check guide roller tighness and condition All location Good( ) / Not Good( )
8. Support roller
- Check support roller, bearing and shaft condition All location Good( ) / Not Good( )
1. Cylinder
- Check abnormal sound and cylinder condition
- Check hose and any leakage All cylinders Good( ) / Not Good( )
Note : Fill up where applicable
2. Cross joint
- Check vibration and any abnormal sound All location Good( ) / Not Good( )
- Check bearing and shaft condition All location Good( ) / Not Good( )
3. Sheave
- Check bolt tighness, sheave and bearing condition All location Good( ) / Not Good( )
4. Limit switch
- Check limit switch condition and functionality All limit switches Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 17 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 8 of 8
1. Festoon rail
- Check deformation, dents and leveling condition Along rails Good( ) / Not Good( )
2. Festoon cable
- Check cable and cable clamp mouting condition All cables Good( ) / Not Good( )
4. Festoon bumper
- Check mounting and bumber condition All bumpers Good( ) / Not Good( )
6. Belting system
- Check belting, pulley and bearing condition Motor #1 and #2 Good( ) / Not Good( )
Note : Fill up where applicable
9. Festoon carrier
- Check carrier condition All carrier Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 18 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 1 of 4
1. Gantry brake
- Check wire termination
- Check friction disc, stationary disc and coil assembly All brakes Good( ) / Not Good( )
- Check mounting cover and silicon seal condition
Note : Fill up where applicable
Seaside
Height : #1 : ______ mm #5 : ______ mm) Good( ) / Not Good( )
Height : #2 : ______ mm #6 : ______ mm) Good( ) / Not Good( )
Height : #3 : ______ mm #7 : ______ mm) Good( ) / Not Good( )
Height : #4 : ______ mm #8 : ______ mm) Good( ) / Not Good( )
Seaside
Torque : #1 : ______ Nm #5 : ______ Nm) Good( ) / Not Good( )
Torque : #2 : ______ Nm #6 : ______ Nm) Good( ) / Not Good( )
Torque : #3 : ______ Nm #7 : ______ Nm) Good( ) / Not Good( )
Torque : #4 : ______ Nm #8 : ______ Nm) Good( ) / Not Good( )
4. Air gap
- Check any rubbing All brakes Good( ) / Not Good( )
Note : Fill up where applicable
6. Brake pad and disc (Seaside) Brake #1 RHS : _____mm, LHS _____mm Good( ) / Not Good( )
- Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm) Disc : _____mm Good( ) / Not Good( )
- Check and clean disc surface
Note : Fill up where applicable Brake #2 RHS : _____mm, LHS _____mm Good( ) / Not Good( )
Disc : _____mm Good( ) / Not Good( )
8. Servolifter / Thruster
- Inspect oil, electrical and mechanical part All servolifters Good( ) / Not Good( )
Note : Fill up where applicable
1. Gearbox oil
- Inspect oil level and oil condition All gearboxes Good( ) / Not Good( )
2. Structure
- Inspect mounting bolts tightness and crack All gearboxes Good( ) / Not Good( )
Note : Fill up where applicable
3. Bearing
- Inspect abnormal sound All gearboxes Good( ) / Not Good( )
Note : Fill up where applicable
5. Coupling
- Check rubber insert for coupling condition
- Check circlips condition All couplings Good( ) / Not Good( )
Note : Fill up where applicable
1. Sound inspection
- Check any abnormal sound All motors Good( ) / Not Good( )
2. Electrical
- Check wire termination at motor termination box All motors Good( ) / Not Good( )
3. Structure
- Check cover, mounting and body codition All motors Good( ) / Not Good( )
3. Limit switch
- Check condition and functionality All location Good( ) / Not Good( )
- Check leakage and mounting condition
4. Structure
- Check any leakage and cylinder condition
- Check brake shoe / lining condition All location Good( ) / Not Good( )
- Check mounting condition
Note : Fill up where applicable
2. Wire rope
- Check wire rope rusty and stringness Right and left side of boom girder Good( ) / Not Good( )
Note : Fill up where applicable
1. Siren
- Check siren functionality and condition All sirens Good( ) / Not Good( )
- Check wire termination condition
2. Warning light
- Check bulb and motor condition
- Check lamp cover and mounting condition All warning lights Good( ) / Not Good( )
- Check wire termination condition
1. Wheel
- Check wheel bearing condition and abnormal sound All wheels Good( ) / Not Good( )
2. Structure
- Check wheel flange cracks or damages and condition All wheels Good( ) / Not Good( )
- Check mounting condition
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 22 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 1 of 5
1. Reserve stroke height (10 mm) Brake #1 (Height : _________ mm) Good( ) / Not Good( )
- Inspect stroke indicator setting and manual release
2. Braking torque
- Inspect setting and mechanical component Brake #1 (Torque : ________________ Nm) Good( ) / Not Good( )
Note : IMPSA-A : ≥ 1890Nm, NOELL/MITSUI/ZPMC-A: ≥ 14850 Nm,
IMPSA-B : >7200Nm, ZPMC-B : >5940Nm, ZPMC-C: >6000Nm
3. Air gap
- Check any rubbing Service brake Good( ) / Not Good( )
4. Brake pad and disc Brake pad RHS : ________mm Good( ) / Not Good( )
- Check and clean disc surface Brake pad LHS : ________mm Good( ) / Not Good( )
- Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm) Brake disc : ________mm Good( ) / Not Good( )
ZPMC (Pad : >3.0 mm, Disc : >1.0mm wear on each side)
6. Check wedge and shackle kit Service brake Good( ) / Not Good( )
7. Servolifter / Thruster
- Inspect oil, electrical and mechanical part Service brake Good( ) / Not Good( )
8. Structure
- Check pivot pin, linkage and mounting Good( ) / Not Good( )
4. Brake pad and disc Brake #1 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
- Inspect pad and disc (Pad : ≥ 8 mm, Disc : ≥ 28 mm) Brake #1 LHS : ______mm Good( ) / Not Good( )
- Check and clean disc surface Brake #2 RHS : ______mm Good( ) / Not Good( )
Note : Fill up where applicable Brake #2 LHS : ______mm Good( ) / Not Good( )
1. Gearbox oil
- Inspect oil level and oil condition Gearbox #1 Good( ) / Not Good( )
2. Structure
- Inspect mounting bolts tightness and crack Gearbox #1 Good( ) / Not Good( )
3. Bearing
- Inspect abnormal sound Gearbox #1 Good( ) / Not Good( )
2. Visual check
- Check structure and wire termination Boom motor Good( ) / Not Good( )
3. Emergency Motor
- Check coupling condition Boom emergency motor Good( ) / Not Good( )
- Check limit switch working condition
1. Visual check
- Check broken strands, deformation and kinks Wire rope drum Good( ) / Not Good( )
- Broken strands (<18 wires) Boom tip Good( ) / Not Good( )
- Diameter : IMPSA-A : >28.8mm, IMPSA-B : >34.2mm, A-Frame Good( ) / Not Good( )
ZPMC-A/C : 36mm~33.4mm, ZPMC-B : 32.4mm
NOELL/MITSUI : 30mm~2 7.9mm
4. Support plate
- Check condition All plates Good( ) / Not Good( )
2. Check bearing any abnormal noise All drums Good( ) / Not Good( )
1. Check groove condition any damaged or rope trace mark Boom tip Good( ) / Not Good( )
A-Frame Good( ) / Not Good( )
2. Check locking / keeper plate condition Boom tip Good( ) / Not Good( )
A-Frame Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 25 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 4 of 5
1. Cable / conduit
- Check cable condition, insulation and cable lug A-Frame Good( ) / Not Good( )
2. Limit switch
- Check positioning, rusty, functionality and mounting A-Frame Good( ) / Not Good( )
3. Striker
- Check condition A-Frame Good( ) / Not Good( )
1. Cable termination
- Check cable damage and breakage at cable lugs Boom drum Good( ) / Not Good( )
6. Driven pulley
- Check pulley mounting, side guide, wear and crack Boom drum Good( ) / Not Good( )
Note : Fill up where applicable
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 26 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 5 of 5
1. Servolifter
- Check oil condition and any leakage
- Check linkage split-pin and conduit condition A-Frame Good( ) / Not Good( )
- Check rubber bumper
Note : Fill up where applicable
2. Limit Switch
- Check condition and functionality All limit switches Good( ) / Not Good( )
Note : Fill up where applicable
4. Power pack
- Check oil condition and any leakage A-Frame Good( ) / Not Good( )
Note : Fill up where applicable
5. Plunger
- Check plunger and spring condition A-Frame Good( ) / Not Good( )
Note : Fill up where applicable
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 27 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 1 of 3
4. Backreach
- Check functionality and condition Backreach Good( ) / Not Good( )
- Check wire termination Multi-functional platform Good( ) / Not Good( )
Note : Fill up where applicable
5. Portal beam
- Check functionality and condition Right hand side Good( ) / Not Good( )
- Check wire termination Left hand side Good( ) / Not Good( )
Note : Fill up where applicable
4. Indicator light
- Check functionality and condition All location Good( ) / Not Good( )
- Check wire termination
6. Foot siren
- Check functionality and condition Siren Good( ) / Not Good( )
- Check wire termination
9. Operator seat
- Check functionality and condition Operator seat Good( ) / Not Good( )
1. Compressor
- Check structure and condition Control room Good( ) / Not Good( )
- Check wire termination and functionality Operator cabin Good( ) / Not Good( )
- Check gas quantity and any leakage Checker cabin Good( ) / Not Good( )
Note : Fill up where applicable
2. Indoor unit
- Check structure and condition Control room Good( ) / Not Good( )
- Check wire termination and functionality Operator cabin Good( ) / Not Good( )
Note : Fill up where applicable Checker cabin Good( ) / Not Good( )
4. Mechanical part
- Check blower motor mounting condition All location Good( ) / Not Good( )
- Check belting condition
- Check cleanliness
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 30 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
1. Trolley system
- Pump-in new grease into greasing point Trolley sheave Done( ) / Not Done( )
Note : Fill up where applicable Trolley floating shaft Done( ) / Not Done( )
Trolley plumber block Done( ) / Not Done( )
Catenary wheel Done( ) / Not Done( )
Catenary sheave Done( ) / Not Done( )
Catenary McGill guide roller Done( ) / Not Done( )
Backreach-catenary sheave Done( ) / Not Done( )
Backreach rope tensioner bearing Done( ) / Not Done( )
1. Boom system
- Pump-in new grease into greasing point Boom drum Done( ) / Not Done( )
Note : Fill up where applicable
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 31 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 1 of 3
1. Guide rail
- Check buffer spring and rail condition All location Good( ) / Not Good( )
- Check mounting condition
2. Gear
- Check rack and pinion gear condition All location Good( ) / Not Good( )
4. Motor
- Check casing and mounting condition Top of cabin Good( ) / Not Good( )
5. Brake
- Check functionality and brake condition All brakes Good( ) / Not Good( )
6. Cabin level
- Check setting on each floor level All floors Good( ) / Not Good( )
7. Push button
- Check functionality and condition All push buttons Good( ) / Not Good( )
8. Cable
- Check cable insulation and condition Power cable Good( ) / Not Good( )
- Check protection rubber and mounting condition
9. Carrier structure
- Check door and roof door condition Carrier Good( ) / Not Good( )
- Check ladder condition
10. Intercomm
- Check condition and functionality Inside carrier Good( ) / Not Good( )
1. Electrical part
- Check AC power LED light up Machinery house
- Determine standby battery condition ( 25.5 ≤ x ≤ 26.6 Vdc ) - Zone 1 Good( ) / Not Good( )
- Check any alarm LED light up from panel - Zone 2 Good( ) / Not Good( )
- Fire, Fault, Off, Extinguisher release, Walk test, External - Zone 3 Good( ) / Not Good( )
acoustic alarm off, CPU fault, Power supply fault. - Zone 4 Good( ) / Not Good( )
- Any fault message on the display (Stated the fault message) - Main Good( ) / Not Good( )
Note : Fill up where applicable - Charger Good( ) / Not Good( )
- Evacuate Good( ) / Not Good( )
2. Mechanical Part
- Visual Check for cylinder pressure gauge reading
(±170 bar for 225 bar system) Good( ) / Not Good( )
- Examine cylinder valve and hoses for sign of damage,
wear or leakage Good( ) / Not Good( )
- Inspect all piping & nozzles for any sign damage & leakage Good( ) / Not Good( )
Note : Fill up where applicable
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 32 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 2 of 3
2. Control console
- Check functionality and condition Machinery house Good( ) / Not Good( )
- Check structure
3. Structure
- Check structure condition Rubber buffer Good( ) / Not Good( )
- Check hook and latch condition Hook block Good( ) / Not Good( )
5. Electrical part
- Check wire termination and contactor condition Electrical box Good( ) / Not Good( )
1. Compressor
- Check oil level sufficient, air filter, V-belt, pressure gauge, Machinery house Good( ) / Not Good( )
safety valve, piping and mounting condition
- Check any abnormal sound or vibration
2. Pressure Switch
- Check pressure setting Machinery house Good( ) / Not Good( )
Note : Cut in: 9.9 kg/cm2 & Cut out: 8.0 kg/cm2
- Adjusting screw locknut and check wire termination
3. Motor
- Check mounting and any abnormal sound Machinery house Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 33 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 3 of 3
2. Check lighting condition and functionality Cabin ceiling Good( ) / Not Good( )
3. Intercomm
- Check condition and functionality Good( ) / Not Good( )
4. Structure
- Check mounting and condition All location Good( ) / Not Good( )
- Check door and glass
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 34 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM: Page 1 of 1
1. Bushing
- Check abnormal sound and vibration All location Good( ) / Not Good( )
3. Rest support
- Check forestay rest support condition All supports Good( ) / Not Good( )
4. Boom buffer
- Check condition and mounting A-Frame Good( ) / Not Good( )
3. Structure
- Check mounting and condition All sheaves Good( ) / Not Good( )
1. Indicator bulb
- Check condition and functionality All indicators bulbs Good( ) / Not Good( )
2. Check lighting condition and functionality Cabin ceiling Good( ) / Not Good( )
3. Structure
- Check mounting and condition All location Good( ) / Not Good( )
- Check door and glass
4. Intercomm
- Check condition and functionality Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 35 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
1. Gantry system
- Pump-in new grease into greasing point All boggies Done( ) / Not Done( )
1. Boom system
- Pump-in new grease into greasing point All boom sheaves Done( ) / Not Done( )
1. Motor
- Check mounting and condition Main cable reel motor Good( ) / Not Good( )
2. Main cable
- Check cable condition Main power cable Good( ) / Not Good( )
3. Structure
- Check mounting and condition All mounting Good( ) / Not Good( )
4. Slip ring
- Check slip rings condition Good( ) / Not Good( )
5. Gearbox
- Check gearbox oil condition Good( ) / Not Good( )
- Check mounting and condition Good( ) / Not Good( )
- Check any abnormal sound Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 37 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
1. Boom backstay
- Pump-in new grease into greasing point All greasing points Done( ) / Not Done( )
Note : Fill up where applicable
1. KBT coupling
- Pump-in new grease into greasing point Done( ) / Not Done( )
Note : Fill up where applicable
Please see attachment (No. : )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 38 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AC/DC MEGGER : Page 1 of 1
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 1 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
QUAY CRANE
PREVENTIVE MAINTENANCE CHECKLIST
MONTH / YEAR :
CRANE NUMBER :
JOB NUMBER :
W.O. NUMBER :
DATE/TIME END :
CRANE :
TROLLEY :
GANTRY :
BOOM :
PM CHECKLIST TYPE :
Please tick ( X ) where applicable :
MONTHLY PM : Page 1 to page 30 ( )
TROLLEY SYSTEM
Date :
GANTRY SYSTEM
Date :
BOOM SYSTEM
Date :
AUXIALLARY SYSTEM
Date :
GREASING
Date :
VERIFIED BY : SIGNATURE :
Date :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 2 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 1 of 8
1. Reserve stroke height Brake #1 (Height : _________ mm) Good( ) / Not Good( )
- Inspect stroke indicator setting and manual release Brake #2 (Height : _________ mm) Good( ) / Not Good( )
Note : Burbenzer brake 25mm Brake #3 (Height : _________ mm) Good( ) / Not Good( )
ZPMC Brake 10mm Brake #4 (Height : _________ mm) Good( ) / Not Good( )
2. Braking torque
Brake #1 (Torque : ________________ Nm) Good( ) / Not Good( )
- Inspect setting and mechanical component Brake #2 (Torque : ________________ Nm) Good( ) / Not Good( )
Note : Brake #3 (Torque : ________________ Nm) Good( ) / Not Good( )
ZPMC-C : 19kNm Brake #4 (Torque : ________________ Nm) Good( ) / Not Good( )
3. Air gap
- Check any rubbing All brakes Good( ) / Not Good( )
4. Brake pad and disc Brake #1 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
- Inspect pad and disc Brake #1 LHS : ______mm Good( ) / Not Good( )
- Check and clean disc surface Brake #2 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
Note : Fill up where applicable Brake #2 LHS : ______mm Good( ) / Not Good( )
ZPMC-C (Pad : > 3 mm, Disc wear more than 20%) Brake #3 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
Brake #3 LHS : ______mm Good( ) / Not Good( )
Brake #4 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
Brake #4 LHS : ______mm Good( ) / Not Good( )
8. Structure
- Check pivot pin, linkage and mounting Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 3 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 2 of 8
3. Proximity sensor
- Check setting and functionality Brake #1 Good( ) / Not Good( )
Note : Fill up where applicable Brake #2 Good( ) / Not Good( )
Brake #3 Good( ) / Not Good( )
Brake #4 Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 4 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 3 of 8
1. Gearbox oil
- Inspect oil level and oil condition Gearbox #1 (Main) Good( ) / Not Good( )
Note : Fill up where applicable Gearbox #2 (Aux) Good( ) / Not Good( )
2. Structure
- Inspect mounting bolts tightness and crack Gearbox #1 (Main) Good( ) / Not Good( )
Note : Fill up where applicable Gearbox #2 (Aux) Good( ) / Not Good( )
3. Bearing
- Inspect abnormal sound Gearbox #1 (Main) Good( ) / Not Good( )
Note : Fill up where applicable Gearbox #2 (Aux) Good( ) / Not Good( )
3. Visual check
- Check coupling motor & gear box (Bush Coupling) Motor #1 Good( ) / Not Good( )
- Check terminations Motor #2 Good( ) / Not Good( )
- Check mounting bolts and frame Motor #3 Good( ) / Not Good( )
Note : Fill up where applicable Motor #4 Good( ) / Not Good( )
4. Check blower motor cond. Motor #1 ( 1._____ A 2. _____ A 3. _____ A) Good( ) / Not Good( )
- Check rotation Motor #2 ( 1._____ A 2. _____ A 3. _____ A) Good( ) / Not Good( )
- Check running cond Motor #3 ( 1._____ A 2. _____ A 3. _____ A) Good( ) / Not Good( )
- Measure motor demands Motor #4 ( 1._____ A 2. _____ A 3. _____ A) Good( ) / Not Good( )
- Check coupling condition
5. Emergency Motor
- Check coupling condition & chain link Motor #1 Good( ) / Not Good( )
- Check limit switch working condition Motor #2 Good( ) / Not Good( )
1. Visual check
- Check broken strands, deformation and kinks Drum Good( ) / Not Good( )
- Diameter (ZPMC-C : 32.00mm~29.76mm) Backreach Good( ) / Not Good( )
- Broken strands (<18 wires) Trolley platform Good( ) / Not Good( )
Note : Fill up where applicable Headblock Good( ) / Not Good( )
Main Girder Area (5 mtr before Joint) Good( ) / Not Good( )
Boom Girder Area (5 mtr after Joint) Good( ) / Not Good( )
2. Check bearing any abnormal noise All drums Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 6 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 5 of 8
1. Check groove condition any damaged or rope trace mark Backreach Good( ) / Not Good( )
Note : Fill up where applicable Trolley platform Good( ) / Not Good( )
Headblock Good( ) / Not Good( )
Boom tip Good( ) / Not Good( )
4. Structure
- Check bolt tightness and condition All couplings Tight ( ) / Loose( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 7 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 6 of 8
1. Cable termination
- Check cable damage and breakage at cable lugs Main hoist drum Good( ) / Not Good( )
4. Check cam switch set Main hoist drum Good( ) / Not Good( )
- Check mounted bolt tightness
1. Cable / conduit
- Check cable condition, insulation and cable lug Trolley platform / trolley house Good( ) / Not Good( )
2. Limit switch
- Check positioning Trolley platform / trolley house Good( ) / Not Good( )
- Check rusty Good( ) / Not Good( )
- Check functionality Good( ) / Not Good( )
- Check mounting Good( ) / Not Good( )
3. Striker
- Check condition Spreader cable / headblock Good( ) / Not Good( )
Note : Fill up where applicable
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 8 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 7 of 8
1. Coupling
- Check mounting Main hoist motor and drum Tight( ) / Loose ( )
- Check rusty Not rusted( ) / Rusted( )
- Check alignment Good( ) / Not Good( )
2. Coupling Reducer
- Check condition Main hoist drum Good( ) / Not Good( )
3. Electrical Termination
- Check cable connection Main hoist drum Good( ) / Not Good( )
Note : Fill up where applicable
1. Cable termination
- Check cable damage and breakage at cable lugs Main hoist drum Good( ) / Not Good( )
2. Coupling tightness
- Check bolt tightness All couplings Tight ( ) / Loose ( )
3. Magnetic Clutch
- Check bearings condition Motor# 1 Unwear( ) / Wear( )
Motor# 2 Unwear( ) / Wear( )
Motor# 3 Unwear( ) / Wear( )
Motor# 4 Unwear( ) / Wear( )
- Check for noisy sound Motor# 1 Normal( ) / Abnormal( )
Motor# 2 Normal( ) / Abnormal( )
Motor# 3 Normal( ) / Abnormal( )
Motor# 4 Normal( ) / Abnormal( )
- Check air gap Motor# 1 ( _____ A; _____mm ) Good( ) / Not Good( )
- Measure current demand Motor# 2 ( _____ A; _____mm ) Good( ) / Not Good( )
Motor# 3 ( _____ A; _____mm ) Good( ) / Not Good( )
Motor# 4 ( _____ A; _____mm ) Good( ) / Not Good( )
4. Electrical
- Check cable connection and slip ring carbon brushes Trolley platform Good( ) / Not Good( )
- Check short length cable and junction box Headblock Good( ) / Not Good( )
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 9 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 8 of 8
5. Limit switch
- Check limit switch condition Trolley platform Good( ) / Not Good( )
6. Absorber
- Check condition Headblock Good( ) / Not Good( )
1. Twistlock
- Check gap, lock pin and condition All twistlocks Unwear( ) / Wear( )
No Crack( ) / Crack ( )
2. Switches
- Check headblock connected cond. Headblock lock/unlock lever Good( ) / Not Good( )
- Check headblock anchor sensor cond. Headblock lock/unlock lever Good( ) / Not Good( )
1. Power pack
- Check oil level, condition and cleanliness TLS platform Good( ) / Not Good( )
- Check working pressure (160±10 psi) Pressure : _________ psi Good( ) / Not Good( )
- Check hose, valve and piping No leak( ) / Leak( )
2. Hydraulic cylinder
- Check oil leak TLS platform No Leak( ) / Leak( )
- Check guide roller Unwear( ) / Wear( )
- Check piston surface condition Smoothed( ) / Scratched( )
3. Positioner sensor
- Check mounting All cylinders Tight( ) / Loose( )
- Check crack No crack( ) / Crack( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 10 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 1 of 8
1. Reserve stroke height Brake #1 (Height : _________ mm) Good( ) / Not Good( )
- Inspect stroke indicator setting and manual release
Note : Burbenzer brake 25mm
ZPMC Brake 10mm
2. Braking torque
Brake #1 (Torque : ________________ Nm) Good( ) / Not Good( )
- Inspect setting and mechanical component
Note : IMPSA-A : ≥ 977Nm, NOELL /MITSUI/ZPMC-A : ≥ 1890Nm
IMPSA-B : ≥ 977Nm, ZPMC-B : ≥ 5175 Nm, ZPMC-C : 5500Nm
3. Air gap
- Check any rubbing All brakes Good( ) / Not Good( )
4. Brake pad and disc Brake #1 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
- Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm) Brake #1 LHS : ______mm Good( ) / Not Good( )
ZPMC-C: Disk wear >20% from 30mm, Pad >3mm
ZPMC(Pad : ≥ 3 mm, Disc : ≤ 1.0mm wear on each side)
- Check and clean disc surface
Note : Fill up where applicable
8. Structure
- Check pivot pin, linkage and mounting Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 11 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 2 of 8
2. Emergency motor
- Check coupling condition Motor #1 Good( ) / Not Good( )
- Check limit switch working condition
1. Visual check
- Check broken strands, deformation and kinks Drum Good( ) / Not Good( )
- Diameter ( 24.18mm to 26.00mm) Backreach Good( ) / Not Good( )
- Broken strands (<18 wires) Trolley platform Good( ) / Not Good( )
Note : Fill up where applicable Boom tip Good( ) / Not Good( )
2. Check bearing any abnormal noise All drums Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 13 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 4 of 8
1. Check groove condition any damaged or rope trace mark Backreach Good( ) / Not Good( )
Note : Fill up where applicable Trolley platform Good( ) / Not Good( )
Boom tip Good( ) / Not Good( )
4. Structure
- Check bolt tightness and condition All couplings Good( ) / Not Good( )
2. Limit switch
- Check condtion, mounting and functionality All limit switches Good( ) / Not Good( )
3. Flag sensor
- Check condtion, mounting and functionality All flag sensors Good( ) / Not Good( )
1. Coupling
- Check mounting, rusty, alignment and sprider wear Trolley motor Good( ) / Not Good( )
Note : Fill up where applicable
2. Electrical
- Check cable connection Trolley motor Good( ) / Not Good( )
3. Structure
- Check mounting, wheel and bearing condition Trolley LS LHS Good( ) / Not Good( )
Note : Fill up where applicable
4. Encoder sensor
- Check sensor surface and condition Trolley motor Good( ) / Not Good( )
1. Wheel bearings
- Check abnormal noise All location Good( ) / Not Good( )
2. Trolley wheel
- Check any crack or damage on wheel flange All wheels Good( ) / Not Good( )
- Check wheel bracket bolts tighten All wheel brackets Good( ) / Not Good( )
- Check wheel cover bolt tightness All bolts Good( ) / Not Good( )
Note : Fill up where applicable
6. Structure
- Check catenary structure condition 1. Catenary Landside Good( ) / Not Good( )
Note : Fill up where applicable 2. Catenary Seaside Good( ) / Not Good( )
7. Guide roller
- Check guide roller tighness and condition All location Good( ) / Not Good( )
8. Support roller
- Check support roller, bearing and shaft condition All location Good( ) / Not Good( )
1. Cylinder
- Check abnormal sound and cylinder condition
- Check hose and any leakage All cylinders Good( ) / Not Good( )
Note : Fill up where applicable
2. Cross joint
- Check vibration and any abnormal sound All location Good( ) / Not Good( )
- Check bearing and shaft condition All location Good( ) / Not Good( )
3. Sheave
- Check bolt tighness, sheave and bearing condition All location Good( ) / Not Good( )
4. Limit switch
- Check limit switch condition and functionality All limit switches Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 17 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 8 of 8
1. Festoon rail
- Check deformation, dents and leveling condition Along rails Good( ) / Not Good( )
2. Festoon cable
- Check cable and cable clamp mouting condition All cables Good( ) / Not Good( )
4. Festoon bumper
- Check mounting and bumber condition All bumpers Good( ) / Not Good( )
6. Belting system
- Check belting, pulley and bearing condition Motor #1 Good( ) / Not Good( )
Note : Fill up where applicable Motor #2 Good( ) / Not Good( )
Motor #3 Good( ) / Not Good( )
9. Festoon carrier
- Check carrier condition All carrier Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 18 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 1 of 4
1. Gantry brake
- Check wire termination
- Check friction disc, stationary disc and coil assembly All brakes Good( ) / Not Good( )
- Check mounting cover and silicon seal condition
Note : Fill up where applicable
Seaside
Height : #1 : ______ mm #5 : ______ mm) Good( ) / Not Good( )
Height : #2 : ______ mm #6 : ______ mm) Good( ) / Not Good( )
Height : #3 : ______ mm #7 : ______ mm) Good( ) / Not Good( )
Height : #4 : ______ mm #8 : ______ mm) Good( ) / Not Good( )
Seaside
Torque : #1 : ______ Nm #5 : ______ Nm) Good( ) / Not Good( )
Torque : #2 : ______ Nm #6 : ______ Nm) Good( ) / Not Good( )
Torque : #3 : ______ Nm #7 : ______ Nm) Good( ) / Not Good( )
Torque : #4 : ______ Nm #8 : ______ Nm) Good( ) / Not Good( )
4. Air gap
- Check any rubbing All brakes Good( ) / Not Good( )
Note : Fill up where applicable
6. Brake pad and disc (Seaside) Brake #1 RHS : _____mm, LHS _____mm Good( ) / Not Good( )
- Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm) Disc : _____mm Good( ) / Not Good( )
- Check and clean disc surface
Note : Fill up where applicable Brake #2 RHS : _____mm, LHS _____mm Good( ) / Not Good( )
Disc : _____mm Good( ) / Not Good( )
8. Servolifter / Thruster
- Inspect oil, electrical and mechanical part All servolifters Good( ) / Not Good( )
Note : Fill up where applicable
1. Gearbox oil
- Inspect oil level and oil condition All gearboxes Good( ) / Not Good( )
2. Structure
- Inspect mounting bolts tightness and crack All gearboxes Good( ) / Not Good( )
Note : Fill up where applicable
3. Bearing
- Inspect abnormal sound All gearboxes Good( ) / Not Good( )
Note : Fill up where applicable
5. Coupling
- Check rubber insert for coupling condition
- Check circlips condition All couplings Good( ) / Not Good( )
Note : Fill up where applicable
6. Housekeeping All location Done( ) / Not Done( )
1. Sound inspection
- Check any abnormal sound All motors Good( ) / Not Good( )
2. Electrical
- Check wire termination at motor termination box All motors Good( ) / Not Good( )
3. Structure
- Check cover, mounting and body codition All motors Good( ) / Not Good( )
3. Limit switch
- Check condition and functionality All location Good( ) / Not Good( )
- Check leakage and mounting condition
4. Structure
- Check any leakage and cylinder condition
- Check brake shoe / lining condition All location Good( ) / Not Good( )
- Check mounting condition
Note : Fill up where applicable
2. Wire rope
- Check wire rope rusty and stringness Right and left side of boom girder Good( ) / Not Good( )
Note : Fill up where applicable
1. Siren
- Check siren functionality and condition All sirens Good( ) / Not Good( )
- Check wire termination condition
2. Warning light
- Check bulb and motor condition
- Check lamp cover and mounting condition All warning lights Good( ) / Not Good( )
- Check wire termination condition
1. Wheel
- Check wheel bearing condition and abnormal sound All wheels Good( ) / Not Good( )
2. Structure
- Check wheel flange cracks or damages and condition All wheels Good( ) / Not Good( )
- Check mounting condition
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 22 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 1 of 5
1. Reserve stroke height Brake #1 (Height : _________ mm) Good( ) / Not Good( )
- Inspect stroke indicator setting and manual release
Note : Burbenzer brake 25mm
ZPMC brake 10mm
2. Braking torque
- Inspect setting and mechanical component Brake #1 (Torque : ________________ Nm) Good( ) / Not Good( )
Note : IMPSA-A : ≥ 1890Nm, NOELL/MITSUI/ZPMC-A: ≥ 14850 Nm,
IMPSA-B : >7200Nm, ZPMC-B : >5940Nm, ZPMC-C: >6000Nm
3. Air gap
- Check any rubbing Service brake Good( ) / Not Good( )
4. Brake pad and disc Brake pad RHS : ________mm Good( ) / Not Good( )
- Check and clean disc surface Brake pad LHS : ________mm Good( ) / Not Good( )
- Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm) Brake disc : ________mm Good( ) / Not Good( )
ZPMC (Pad : >3.0 mm, Disc : >1.0mm wear on each side)
6. Check wedge and shackle kit Service brake Good( ) / Not Good( )
Note : Applicable for Burbenzer brake only
7. Servolifter / Thruster
- Inspect oil, electrical and mechanical part Service brake Good( ) / Not Good( )
8. Structure
- Check pivot pin, linkage and mounting Good( ) / Not Good( )
4. Brake pad and disc Brake #1 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
- Inspect pad and disc (Pad : ≥ 8 mm, Disc : ≥ 28 mm) Brake #1 LHS : ______mm Good( ) / Not Good( )
- Check and clean disc surface Brake #2 RHS : ______mm Good( ) / Not Good( )
Note : Fill up where applicable Brake #2 LHS : ______mm Good( ) / Not Good( )
1. Gearbox oil
- Inspect oil level and oil condition Gearbox #1 Good( ) / Not Good( )
2. Structure
- Inspect mounting bolts tightness and crack Gearbox #1 Good( ) / Not Good( )
3. Bearing
- Inspect abnormal sound Gearbox #1 Good( ) / Not Good( )
2. Visual check
- Check structure and wire termination Boom motor Good( ) / Not Good( )
3. Emergency Motor
- Check coupling condition Boom emergency motor Good( ) / Not Good( )
- Check limit switch working condition
1. Visual check
- Check broken strands, deformation and kinks Wire rope drum Good( ) / Not Good( )
- Broken strands (<18 wires) Boom tip Good( ) / Not Good( )
- Diameter : IMPSA-A : >28.8mm, IMPSA-B : >34.2mm, A-Frame Good( ) / Not Good( )
ZPMC-A/C : 36mm~33.4mm, ZPMC-B : 32.4mm
NOELL/MITSUI : 30mm~2 7.9mm
4. Support plate
- Check condition All plates Good( ) / Not Good( )
2. Check bearing any abnormal noise All drums Good( ) / Not Good( )
1. Check groove condition any damaged or rope trace mark Boom tip Good( ) / Not Good( )
A-Frame Good( ) / Not Good( )
2. Check locking / keeper plate condition Boom tip Good( ) / Not Good( )
A-Frame Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 25 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 4 of 5
1. Cable / conduit
- Check cable condition, insulation and cable lug A-Frame Good( ) / Not Good( )
2. Limit switch
- Check positioning, rusty, functionality and mounting A-Frame Good( ) / Not Good( )
3. Striker
- Check condition A-Frame Good( ) / Not Good( )
1. Cable termination
- Check cable damage and breakage at cable lugs Boom drum Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 26 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 5 of 5
1. Servolifter
- Check oil condition and any leakage
- Check linkage split-pin and conduit condition A-Frame Good( ) / Not Good( )
- Check rubber bumper
Note : Fill up where applicable
2. Limit Switch
- Check condition and functionality All limit switches Good( ) / Not Good( )
Note : Fill up where applicable
4. Plunger
- Check plunger and spring condition A-Frame Good( ) / Not Good( )
Note : Fill up where applicable
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 27 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 1 of 3
4. Backreach
- Check functionality and condition Backreach Good( ) / Not Good( )
- Check wire termination Multi-functional platform Good( ) / Not Good( )
Note : Fill up where applicable
5. Portal beam
- Check functionality and condition Right hand side Good( ) / Not Good( )
- Check wire termination Left hand side Good( ) / Not Good( )
Note : Fill up where applicable
4. Indicator light
- Check functionality and condition All location Good( ) / Not Good( )
- Check wire termination
6. Foot siren
- Check functionality and condition Siren Good( ) / Not Good( )
- Check wire termination
9. Operator seat
- Check functionality and condition Operator seat Good( ) / Not Good( )
10. Housekeeping All location Done( ) / Not Done( )
1. Compressor
- Check structure and condition Control room Good( ) / Not Good( )
- Check wire termination and functionality Operator cabin Good( ) / Not Good( )
- Check gas quantity and any leakage Checker cabin Good( ) / Not Good( )
Note : Fill up where applicable
2. Indoor unit
- Check structure and condition Control room Good( ) / Not Good( )
- Check wire termination and functionality Operator cabin Good( ) / Not Good( )
Note : Fill up where applicable Checker cabin Good( ) / Not Good( )
4. Mechanical part
- Check blower motor mounting condition All location Good( ) / Not Good( )
- Check belting condition
- Check cleanliness
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 30 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
1. Trolley system
- Pump-in new grease into greasing point Trolley sheave Done( ) / Not Done( )
Note : Fill up where applicable Trolley plumber block Done( ) / Not Done( )
Catenary wheel Done( ) / Not Done( )
Catenary sheave Done( ) / Not Done( )
Catenary McGill guide roller Done( ) / Not Done( )
Backreach-catenary sheave Done( ) / Not Done( )
Backreach rope tensioner bearing Done( ) / Not Done( )
1. Boom system
- Pump-in new grease into greasing point Boom drum Done( ) / Not Done( )
Note : Fill up where applicable Forestay Done( ) / Not Done( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 31 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 1 of 3
1. Guide rail
- Check buffer spring and rail condition All location Good( ) / Not Good( )
- Check mounting condition
2. Gear
- Check rack and pinion gear condition All location Good( ) / Not Good( )
4. Motor
- Check casing and mounting condition Top of cabin Good( ) / Not Good( )
5. Brake
- Check functionality and brake condition All brakes Good( ) / Not Good( )
6. Cabin level
- Check setting on each floor level All floors Good( ) / Not Good( )
7. Push button
- Check functionality and condition All push buttons Good( ) / Not Good( )
8. Cable
- Check cable insulation and condition Power cable Good( ) / Not Good( )
- Check protection rubber and mounting condition
9. Carrier structure
- Check door and roof door condition Carrier Good( ) / Not Good( )
- Check ladder condition
10. Intercomm
- Check condition and functionality Inside carrier Good( ) / Not Good( )
1. Electrical part
- Check AC power LED light up Machinery house
- Determine standby battery condition ( 25.5 ≤ x ≤ 26.6 Vdc ) - Zone 1 Good( ) / Not Good( )
- Check any alarm LED light up from panel - Zone 2 Good( ) / Not Good( )
- Fire, Fault, Off, Extinguisher release, Walk test, External - Zone 3 Good( ) / Not Good( )
acoustic alarm off, CPU fault, Power supply fault. - Zone 4 Good( ) / Not Good( )
- Any fault message on the display (Stated the fault message) - Main Good( ) / Not Good( )
Note : Fill up where applicable - Charger Good( ) / Not Good( )
- Evacuate Good( ) / Not Good( )
2. Mechanical Part
- Visual Check for cylinder pressure gauge reading
(±170 bar for 225 bar system) Good( ) / Not Good( )
- Examine cylinder valve and hoses for sign of damage,
wear or leakage Good( ) / Not Good( )
- Inspect all piping & nozzles for any sign damage & leakage Good( ) / Not Good( )
Note : Fill up where applicable
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 32 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 2 of 3
2. Control console
- Check functionality and condition Machinery house Good( ) / Not Good( )
- Check structure
3. Structure
- Check structure condition Rubber buffer Good( ) / Not Good( )
- Check hook and latch condition Hook block Good( ) / Not Good( )
5. Electrical part
- Check wire termination and contactor condition Electrical box Good( ) / Not Good( )
1. Compressor
- Check oil level sufficient, air filter, V-belt, pressure gauge, Machinery house Good( ) / Not Good( )
safety valve, piping and mounting condition
- Check any abnormal sound or vibration
2. Pressure Switch
- Check pressure setting Machinery house Good( ) / Not Good( )
Note : Cut in: 9.9 kg/cm2 & Cut out: 8.0 kg/cm2
- Adjusting screw locknut and check wire termination
3. Motor
- Check mounting and any abnormal sound Machinery house Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 33 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 3 of 3
2. Check lighting condition and functionality Cabin ceiling Good( ) / Not Good( )
3. Intercomm
- Check condition and functionality Good( ) / Not Good( )
4. Structure
- Check mounting and condition All location Good( ) / Not Good( )
- Check door and glass
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 34 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM: Page 1 of 1
1. Bushing
- Check abnormal sound and vibration All location Good( ) / Not Good( )
3. Rest support
- Check forestay rest support condition All supports Good( ) / Not Good( )
4. Boom buffer
- Check condition and mounting A-Frame Good( ) / Not Good( )
3. Structure
- Check mounting and condition All sheaves Good( ) / Not Good( )
1. Indicator bulb
- Check condition and functionality All indicators bulbs Good( ) / Not Good( )
2. Check lighting condition and functionality Cabin ceiling Good( ) / Not Good( )
3. Structure
- Check mounting and condition All location Good( ) / Not Good( )
- Check door and glass
4. Intercomm
- Check condition and functionality Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 35 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
1. Gantry system
- Pump-in new grease into greasing point All boggies Done( ) / Not Done( )
1. Boom system
- Pump-in new grease into greasing point All boom sheaves Done( ) / Not Done( )
1. Motor
- Check mounting and condition Main cable reel motor Good( ) / Not Good( )
2. Main cable
- Check cable condition Main power cable Good( ) / Not Good( )
3. Structure
- Check mounting and condition All mounting Good( ) / Not Good( )
4. Slip ring
- Check slip rings condition Good( ) / Not Good( )
5. Gearbox
- Check gearbox oil condition Good( ) / Not Good( )
- Check mounting and condition Good( ) / Not Good( )
- Check any abnormal sound Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 37 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
1. Boom backstay
- Pump-in new grease into greasing point All greasing points Done( ) / Not Done( )
Note : Fill up where applicable
1. KBT coupling
- Pump-in new grease into greasing point Done( ) / Not Done( )
Note : Fill up where applicable
Please see attachment (No. : )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 38 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AC/DC MEGGER : Page 1 of 1
General Remark :
PREVENTIVE MAINTENANCE ACTIVITY
Time
Quantity Required No of Total time Job
FREQ ACTIVITY SEQ DESCRIPTION SUB-TASK (HRS) (per Man Power Required Sequence Remark
person)
10 Main hoist brake inspection
10.1 Service brake
10.2 Emergency Brake
20 Main hoist gearbox inspection
30 Main hoist AC/DC motor inspection
40 Main hoist wire rope inspection
50 Main hoist wire rope drum inspection
60 Main hoist sheave and bearing inspection
MAIN HOIST SYSTEM
70 Main hoist motor and gearbox coupling inspection
80 Main hoist cam switch inspection
90 Main hoist limit switch inspection
100 Main hoist encoder inspection
110 Main hoist over speed detector inspection
120 Spreader cable reel inspection
130 Spreader headblock inspection
140 TLS system inspection
150 Trolley brake inspection
160 Trolley gearbox inspection
170 Trolley motor inspection
180 Trolley wire rope inspection
190 Trolley wire rope drum inspection
200 Trolley sheave and bearing inspection
210 Trolley motor and gearbox coupling inspection
TROLLEY SYSTEM
220 Trolley wheel inspection
230 Trolley rail inspection
240 Trolley limit switch inspection
EVERY 250 Trolley encoder inspection
1 260 Trolley catenary inspection
MONTH 270 Trolley wire rope tensioner inspection
280 Festoon system inspection
290 Gantry brake inspection
300 Gantry gearbox inspection
310 Gantry motor inspection
GANTRY SYSTEM 320 Gantry rail clamp and anchor pin inspection
330 Gantry anti-collision inspection
340 Gantry alarm system inspection
350 Gantry wheel inspection
360 Boom brake inspection
370 Boom gearbox inspection
380 Boom motor inspection
390 Boom wire rope inspection
400 Boom wire rope drum inspection
BOOM SYSTEM
410 Boom sheave and bearing inspection
420 Boom motor and gearbox coupling inspection
430 Boom limit switch inspection
440 Boom cam switch inspection
450 Boom latch inspection
460 Emergency stop system inspection
470 Floodlight inspection
AUXILARY SYSTEM 480 Operator cabin inspection
490 Air-conditioner inspection
500 Software and program monitoring
510 Main hoist system greasing
GREASING 520 Trolley system greasing
530 Boom system greasing
540 Passenger lift inspection
550 Fire alarm system inspection
AUXILARY SYSTEM 560 Maintenance hoist crane inspection
570 Air compressor inspection
580 QC Checker cabin inspection
590 Boom forestay inspection
EVERY BOOM SYSTEM 600 Boom sheave inspection
3 610 Boom cabin inspection
MONTHS 620 Gantry system greasing
630 Boom system greasing
640 Main hoist wire rope lubrication
GREASING
650 Trolley wire rope lubrication
660 Boom wire rope lubrication
670 Caternary wire rope lubrication
GANTRY SYSTEM 680 Main cable reel inspection
690 Backstay pin greasing
GREASING
700 KBT coupling greasing
EVERY 710 Main hoist motor insulation reading
6
MONTHS MEGGER 720 Trolley motor insulation reading
AC & DC MOTOR 730 Boom motor insulation reading
740 Gantry motor insulation reading
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 1 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
QUAY CRANE
PREVENTIVE MAINTENANCE CHECKLIST
MONTH / YEAR :
CRANE NUMBER :
JOB NUMBER :
W.O. NUMBER :
DATE/TIME END :
CRANE :
TROLLEY :
GANTRY :
BOOM :
PM CHECKLIST TYPE :
Please tick ( X ) where applicable :
MONTHLY PM : Page 1 to page 30 ( )
TROLLEY SYSTEM
Date :
GANTRY SYSTEM
Date :
BOOM SYSTEM
Date :
AUXIALLARY SYSTEM
Date :
GREASING
Date :
VERIFIED BY : SIGNATURE :
Date :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 2 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 1 of 8
1. Reserve stroke height (10 mm) Brake #1 (Height : _________ mm) Good( ) / Not Good( )
- Inspect stroke indicator setting and manual release Brake #2 (Height : _________ mm) Good( ) / Not Good( )
Note : Fill up where applicable Brake #3 (Height : _________ mm) Good( ) / Not Good( )
Brake #4 (Height : _________ mm) Good( ) / Not Good( )
2. Braking torque
Brake #1 (Torque : ________________ Nm) Good( ) / Not Good( )
- Inspect setting and mechanical component Brake #2 (Torque : ________________ Nm) Good( ) / Not Good( )
Note : IMPSA-A :≥ 15.75kNm, NOELL/MITSUI : ≥ 14.85kNm, Brake #3 (Torque : ________________ Nm) Good( ) / Not Good( )
IMPSA-B : 27kNm, ZPMC-A : 12.6kNm Brake #4 (Torque : ________________ Nm) Good( ) / Not Good( )
ZPMC-A : ≥ 14.85kNm, ZPMC-C : 19kNm
3. Air gap
- Check any rubbing All brakes Good( ) / Not Good( )
4. Brake pad and disc Brake #1 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
- Inspect pad and disc Brake #1 LHS : ______mm Good( ) / Not Good( )
- Check and clean disc surface Brake #2 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
Note : Fill up where applicable Brake #2 LHS : ______mm Good( ) / Not Good( )
All cranes (Pad : ≥ 5 mm, Disc : ≥ 27 mm) Brake #3 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
ZPMC-B (Pad : ≥ 3 mm, Disc :≤1.0mm wear) Brake #3 LHS : ______mm Good( ) / Not Good( )
ZPMC-C (Pad : > 3 mm, Disc wear more than 20%) Brake #4 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
Brake #4 LHS : ______mm Good( ) / Not Good( )
8. Structure
- Check pivot pin, linkage and mounting Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 3 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 2 of 8
3. Proximity sensor
- Check setting and functionality Good( ) / Not Good( )
Note : Fill up where applicable
4. Motor
- Check electrical and mechanical parts Good( ) / Not Good( )
5. Brake pad and disc Brake #1 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
- Inspect pad and disc (Pad : ≤ 8 mm, Disc : ≥ 28 mm) Brake #1 LHS : ______mm Good( ) / Not Good( )
- Check and clean disc surface
Note : Fill up where applicable Brake #2 RHS : ______mm Good( ) / Not Good( )
Brake #2 LHS : ______mm Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 4 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 3 of 8
1. Gearbox oil
- Inspect oil level and oil condition Gearbox #1 Good( ) / Not Good( )
Note : Fill up where applicable Gearbox #2 Good( ) / Not Good( )
2. Structure
- Inspect mounting bolts tightness and crack Gearbox #1 Good( ) / Not Good( )
Note : Fill up where applicable Gearbox #2 Good( ) / Not Good( )
3. Bearing
- Inspect abnormal sound Gearbox #1 Good( ) / Not Good( )
Note : Fill up where applicable Gearbox #2 Good( ) / Not Good( )
3. Visual check
- Check armature winding for burn marks, scratches Motor #1 Good( ) / Not Good( )
and damages (For DC motor only) Motor #2 Good( ) / Not Good( )
- Check structure and wire termination Motor #3 Good( ) / Not Good( )
Note : Fill up where applicable Motor #4 Good( ) / Not Good( )
4. Check motor in running condition for sparks Motor #1 Good( ) / Not Good( )
Note : For DC motor only Motor #2 Good( ) / Not Good( )
5. Emergency Motor
- Check coupling condition Good( ) / Not Good( )
- Check limit switch working condition
6. Carbon Brush and Holder Motor #1 - Top (8 pcs) Good( ) / Not Good( )
- Check length and condition Motor #1 - Bottom (8 pcs) Good( ) / Not Good( )
Note : For DC motor only Motor #1 - Right (8 pcs) Good( ) / Not Good( )
Motor #1 - Left (8 pcs) Good( ) / Not Good( )
Motor #2 - Top (8 pcs) Good( ) / Not Good( )
Motor #2 - Bottom (8 pcs) Good( ) / Not Good( )
Motor #2 - Right (8 pcs) Good( ) / Not Good( )
Motor #2 - Left (8 pcs) Good( ) / Not Good( )
1. Visual check
- Check broken strands, deformation and kinks Drum Good( ) / Not Good( )
- Diameter (NOELL/ZPMC-A : 26.2mm~28.0mm) Backreach Good( ) / Not Good( )
- Diameter (IMPSA : 26.7mm~28.5mm) Trolley platform Good( ) / Not Good( )
- Diameter (MITSUI : 26.2mm~23.3mm) Headblock Good( ) / Not Good( )
- Diameter (ZPMC-C : 32.00mm~29.76mm)
- Broken strands (<18 wires)
Note : Fill up where applicable
2. Check bearing any abnormal noise All drums Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 6 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 5 of 8
1. Check groove condition any damaged or rope trace mark Backreach Good( ) / Not Good( )
Note : Fill up where applicable Trolley platform Good( ) / Not Good( )
Headblock Good( ) / Not Good( )
Boom tip Good( ) / Not Good( )
4. Structure
- Check bolt tightness and condition All couplings Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 7 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 6 of 8
1. Cable termination
- Check cable damage and breakage at cable lugs Main hoist drum Good( ) / Not Good( )
4. Check 3-way gear condition Main hoist drum Good( ) / Not Good( )
Note : Fill up where applicable
6. Driven pulley
- Check pulley mounting, side guide, wear and crack Main hoist drum Good( ) / Not Good( )
Note : Fill up where applicable
1. Cable / conduit
- Check cable condition, insulation and cable lug Trolley platform / trolley house Good( ) / Not Good( )
2. Limit switch
- Check positioning, rusty, functionality and mounting Trolley platform / trolley house Good( ) / Not Good( )
3. Counter weight
- Check condition Trolley platform / trolley house Good( ) / Not Good( )
Note : Fill up where applicable
4. Striker
- Check condition Spreader cable / headblock Good( ) / Not Good( )
Note : Fill up where applicable
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 8 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 7 of 8
1. Coupling
- Check mounting, rusty, alignment and sprider wear Main hoist motor and drum Good( ) / Not Good( )
Note : Fill up where applicable
3. Driven pulley
- Check pulley mounting, side guide, wear and crack Main hoist drum Good( ) / Not Good( )
Note : Fill up where applicable
4. Electrical
- Check cable connection Main hoist drum Good( ) / Not Good( )
1. Cable termination
- Check cable damage and breakage at cable lugs Main hoist drum Good( ) / Not Good( )
2. Coupling tightness
- Check bolt tightness All couplings Good( ) / Not Good( )
3. Check 3-way gear condition Main hoist drum Good( ) / Not Good( )
Note : Fill up where applicable
1. Spreader drum
- Check drum condition Trolley platform / trolley house Good( ) / Not Good( )
- Check cable condition Good( ) / Not Good( )
4. Electrical
- Check cable connection and slip ring carbon brushes Trolley platform / trolley house Good( ) / Not Good( )
- Check short length cable and junction box Headblock Good( ) / Not Good( )
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 9 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 8 of 8
5. Limit switch
- Check limit switch condition Trolley platform / trolley house Good( ) / Not Good( )
6. Absorber
- Check condition Headblock Good( ) / Not Good( )
1. Twistlock
- Check gap, lock pin and condition All twistlocks Good( ) / Not Good( )
2. Electrical
- Check limit switch and functionality Headblock lock/unlock lever Good( ) / Not Good( )
3. Structure
- Check condition, ladder, hand rail and grating Good( ) / Not Good( )
1. Power pack
- Check oil level, condition and cleanliness
- Check working pressure (160±10 psi) Backreach / TLS platform / trolley house Good( ) / Not Good( )
- Check hose, valve and piping Pressure : _________ psi Good( ) / Not Good( )
2. Hydraulic cylinder
- Check oil leak, guide roller and condition Backreach / TLS platform / trolley house Good( ) / Not Good( )
3. Positioner sensor
- Check wire string, mounting and crack All cylinders Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 10 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 1 of 8
1. Reserve stroke height (10 mm) Brake #1 (Height : _________ mm) Good( ) / Not Good( )
- Inspect stroke indicator setting and manual release Brake #2 (Height : _________ mm) Good( ) / Not Good( )
Note : Fill up where applicable Brake #3 (Height : _________ mm) Good( ) / Not Good( )
Brake #4 (Height : _________ mm) Good( ) / Not Good( )
3. Air gap
- Check any rubbing All brakes Good( ) / Not Good( )
4. Brake pad and disc Brake #1 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
- Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm) Brake #1 LHS : ______mm Good( ) / Not Good( )
ZPMC-C: Disk wear >20% from 30mm, Pad >3mm Brake #2 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
ZPMC(Pad : ≥ 3 mm, Disc : ≤ 1.0mm wear on each side) Brake #2 LHS : ______mm Good( ) / Not Good( )
- Check and clean disc surface Brake #3 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
Note : Fill up where applicable Brake #3 LHS : ______mm Good( ) / Not Good( )
Brake #4 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
Brake #4 LHS : ______mm Good( ) / Not Good( )
8. Structure
- Check pivot pin, linkage and mounting Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 11 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 2 of 8
3. Visual check
- Check armature winding for burn marks, scratches Motor #1 Good( ) / Not Good( )
and damages (For DC motor only) Motor #2 Good( ) / Not Good( )
- Check structure and wire termination Motor #3 Good( ) / Not Good( )
Note : Fill up where applicable Motor #4 Good( ) / Not Good( )
4. Check motor in running condition for sparks Motor #1 Good( ) / Not Good( )
Note : For DC motor only Motor #2 Good( ) / Not Good( )
5. Emergency motor
- Check coupling condition Motor #1 Good( ) / Not Good( )
- Check limit switch working condition Motor #2 Good( ) / Not Good( )
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 12 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 3 of 8
6. Carbon brush and holder Motor #1 - Top (3 pcs) Good( ) / Not Good( )
- Check length and condition Motor #1 - Bottom (3 pcs) Good( ) / Not Good( )
Note : For DC motor only Motor #1 - Right (3 pcs) Good( ) / Not Good( )
Motor #1 - Left (3 pcs) Good( ) / Not Good( )
Motor #2 - Top (3 pcs) Good( ) / Not Good( )
Motor #2 - Bottom (3 pcs) Good( ) / Not Good( )
Motor #2 - Right (3 pcs) Good( ) / Not Good( )
Motor #2 - Left (3 pcs) Good( ) / Not Good( )
1. Visual check
- Check broken strands, deformation and kinks Drum Good( ) / Not Good( )
- Diameter (2 6.2mm~mm) Backreach Good( ) / Not Good( )
- Broken strands (<18 wires) Trolley platform Good( ) / Not Good( )
Note : Fill up where applicable Boom tip Good( ) / Not Good( )
2. Check bearing any abnormal noise All drums Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 13 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 4 of 8
1. Check groove condition any damaged or rope trace mark Backreach Good( ) / Not Good( )
Note : Fill up where applicable Trolley platform Good( ) / Not Good( )
Boom tip Good( ) / Not Good( )
4. Structure
- Check bolt tightness and condition All couplings Good( ) / Not Good( )
2. Limit switch
- Check condtion, mounting and functionality All limit switches Good( ) / Not Good( )
3. Flag sensor
- Check condtion, mounting and functionality All flag sensors Good( ) / Not Good( )
1. Coupling
- Check mounting, rusty, alignment and sprider wear Trolley motor Good( ) / Not Good( )
Note : Fill up where applicable
2. Electrical
- Check cable connection Trolley motor Good( ) / Not Good( )
3. Structure
- Check mounting, wheel and bearing condition Trolley LS LHS Good( ) / Not Good( )
Note : Fill up where applicable
4. Encoder sensor
- Check sensor surface and condition Trolley motor Good( ) / Not Good( )
1. Wheel bearings
- Check abnormal noise All location Good( ) / Not Good( )
2. Trolley wheel
- Check any crack or damage on wheel flange All wheels Good( ) / Not Good( )
- Check wheel bracket bolts tighten All wheel brackets Good( ) / Not Good( )
- Check wheel cover bolt tightness All bolts Good( ) / Not Good( )
Note : Fill up where applicable
6. Structure
- Check catenary structure condition 1. Catenary LHS Good( ) / Not Good( )
Note : Fill up where applicable 2. Catenary RHS Good( ) / Not Good( )
7. Guide roller
- Check guide roller tighness and condition All location Good( ) / Not Good( )
8. Support roller
- Check support roller, bearing and shaft condition All location Good( ) / Not Good( )
1. Cylinder
- Check abnormal sound and cylinder condition
- Check hose and any leakage All cylinders Good( ) / Not Good( )
Note : Fill up where applicable
2. Cross joint
- Check vibration and any abnormal sound All location Good( ) / Not Good( )
- Check bearing and shaft condition All location Good( ) / Not Good( )
3. Sheave
- Check bolt tighness, sheave and bearing condition All location Good( ) / Not Good( )
4. Limit switch
- Check limit switch condition and functionality All limit switches Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 17 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 8 of 8
1. Festoon rail
- Check deformation, dents and leveling condition Along rails Good( ) / Not Good( )
2. Festoon cable
- Check cable and cable clamp mouting condition All cables Good( ) / Not Good( )
4. Festoon bumper
- Check mounting and bumber condition All bumpers Good( ) / Not Good( )
6. Belting system
- Check belting, pulley and bearing condition Motor #1 and #2 Good( ) / Not Good( )
Note : Fill up where applicable
9. Festoon carrier
- Check carrier condition All carrier Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 18 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 1 of 4
1. Gantry brake
- Check wire termination
- Check friction disc, stationary disc and coil assembly All brakes Good( ) / Not Good( )
- Check mounting cover and silicon seal condition
Note : Fill up where applicable
Seaside
Height : #1 : ______ mm #5 : ______ mm) Good( ) / Not Good( )
Height : #2 : ______ mm #6 : ______ mm) Good( ) / Not Good( )
Height : #3 : ______ mm #7 : ______ mm) Good( ) / Not Good( )
Height : #4 : ______ mm #8 : ______ mm) Good( ) / Not Good( )
3. Braking torque
Lanside
- Inspect setting and mechanical component Torque : #1 : ______ Nm #5 : ______ Nm) Good( ) / Not Good( )
Note : Fill up where applicable Torque : #2 : ______ Nm #6 : ______ Nm) Good( ) / Not Good( )
IMPSA-B : > 207Nm, ZPMC-B : >320Nm, ZPMC-C : 350Nm Torque : #3 : ______ Nm #7 : ______ Nm) Good( ) / Not Good( )
Torque : #4 : ______ Nm #8 : ______ Nm) Good( ) / Not Good( )
Seaside
Torque : #1 : ______ Nm #5 : ______ Nm) Good( ) / Not Good( )
Torque : #2 : ______ Nm #6 : ______ Nm) Good( ) / Not Good( )
Torque : #3 : ______ Nm #7 : ______ Nm) Good( ) / Not Good( )
Torque : #4 : ______ Nm #8 : ______ Nm) Good( ) / Not Good( )
4. Air gap
- Check any rubbing All brakes Good( ) / Not Good( )
Note : Fill up where applicable
6. Brake pad and disc (Seaside) Brake #1 RHS : _____mm, LHS _____mm Good( ) / Not Good( )
- Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm) Disc : _____mm Good( ) / Not Good( )
- Check and clean disc surface
Note : Fill up where applicable Brake #2 RHS : _____mm, LHS _____mm Good( ) / Not Good( )
Disc : _____mm Good( ) / Not Good( )
8. Servolifter / Thruster
- Inspect oil, electrical and mechanical part All servolifters Good( ) / Not Good( )
Note : Fill up where applicable
1. Gearbox oil
- Inspect oil level and oil condition All gearboxes Good( ) / Not Good( )
2. Structure
- Inspect mounting bolts tightness and crack All gearboxes Good( ) / Not Good( )
Note : Fill up where applicable
3. Bearing
- Inspect abnormal sound All gearboxes Good( ) / Not Good( )
Note : Fill up where applicable
5. Coupling
- Check rubber insert for coupling condition
- Check circlips condition All couplings Good( ) / Not Good( )
Note : Fill up where applicable
6. Housekeeping All location Done( ) / Not Done( )
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 20 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 3 of 4
1. Sound inspection
- Check any abnormal sound All motors Good( ) / Not Good( )
2. Electrical
- Check wire termination at motor termination box All motors Good( ) / Not Good( )
3. Structure
- Check cover, mounting and body codition All motors Good( ) / Not Good( )
3. Limit switch
- Check condition and functionality All location Good( ) / Not Good( )
- Check leakage and mounting condition
4. Structure
- Check any leakage and cylinder condition
- Check brake shoe / lining condition All location Good( ) / Not Good( )
- Check mounting condition
Note : Fill up where applicable
2. Wire rope
- Check wire rope rusty and stringness Right and left side of boom girder Good( ) / Not Good( )
Note : Fill up where applicable
1. Siren
- Check siren functionality and condition All sirens Good( ) / Not Good( )
- Check wire termination condition
2. Warning light
- Check bulb and motor condition
- Check lamp cover and mounting condition All warning lights Good( ) / Not Good( )
- Check wire termination condition
1. Wheel
- Check wheel bearing condition and abnormal sound All wheels Good( ) / Not Good( )
2. Structure
- Check wheel flange cracks or damages and condition All wheels Good( ) / Not Good( )
- Check mounting condition
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 22 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 1 of 5
1. Reserve stroke height (10 mm) Brake #1 (Height : _________ mm) Good( ) / Not Good( )
- Inspect stroke indicator setting and manual release
2. Braking torque
- Inspect setting and mechanical component Brake #1 (Torque : ________________ Nm) Good( ) / Not Good( )
Note : IMPSA-A : ≥ 1890Nm, NOELL/MITSUI/ZPMC-A: ≥ 14850 Nm,
IMPSA-B : >7200Nm, ZPMC-B : >5940Nm, ZPMC-C: >6000Nm
3. Air gap
- Check any rubbing Service brake Good( ) / Not Good( )
4. Brake pad and disc Brake pad RHS : ________mm Good( ) / Not Good( )
- Check and clean disc surface Brake pad LHS : ________mm Good( ) / Not Good( )
- Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm) Brake disc : ________mm Good( ) / Not Good( )
ZPMC (Pad : >3.0 mm, Disc : >1.0mm wear on each side)
6. Check wedge and shackle kit Service brake Good( ) / Not Good( )
7. Servolifter / Thruster
- Inspect oil, electrical and mechanical part Service brake Good( ) / Not Good( )
8. Structure
- Check pivot pin, linkage and mounting Good( ) / Not Good( )
4. Brake pad and disc Brake #1 RHS : ______mm , Disc : ______mm Good( ) / Not Good( )
- Inspect pad and disc (Pad : ≥ 8 mm, Disc : ≥ 28 mm) Brake #1 LHS : ______mm Good( ) / Not Good( )
- Check and clean disc surface Brake #2 RHS : ______mm Good( ) / Not Good( )
Note : Fill up where applicable Brake #2 LHS : ______mm Good( ) / Not Good( )
1. Gearbox oil
- Inspect oil level and oil condition Gearbox #1 Good( ) / Not Good( )
2. Structure
- Inspect mounting bolts tightness and crack Gearbox #1 Good( ) / Not Good( )
3. Bearing
- Inspect abnormal sound Gearbox #1 Good( ) / Not Good( )
2. Visual check
- Check structure and wire termination Boom motor Good( ) / Not Good( )
3. Emergency Motor
- Check coupling condition Boom emergency motor Good( ) / Not Good( )
- Check limit switch working condition
1. Visual check
- Check broken strands, deformation and kinks Wire rope drum Good( ) / Not Good( )
- Broken strands (<18 wires) Boom tip Good( ) / Not Good( )
- Diameter : IMPSA-A : >28.8mm, IMPSA-B : >34.2mm, A-Frame Good( ) / Not Good( )
ZPMC-A/C : 36mm~33.4mm, ZPMC-B : 32.4mm
NOELL/MITSUI : 30mm~2 7.9mm
4. Support plate
- Check condition All plates Good( ) / Not Good( )
2. Check bearing any abnormal noise All drums Good( ) / Not Good( )
1. Check groove condition any damaged or rope trace mark Boom tip Good( ) / Not Good( )
A-Frame Good( ) / Not Good( )
2. Check locking / keeper plate condition Boom tip Good( ) / Not Good( )
A-Frame Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 25 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 4 of 5
1. Cable / conduit
- Check cable condition, insulation and cable lug A-Frame Good( ) / Not Good( )
2. Limit switch
- Check positioning, rusty, functionality and mounting A-Frame Good( ) / Not Good( )
3. Striker
- Check condition A-Frame Good( ) / Not Good( )
1. Cable termination
- Check cable damage and breakage at cable lugs Boom drum Good( ) / Not Good( )
6. Driven pulley
- Check pulley mounting, side guide, wear and crack Boom drum Good( ) / Not Good( )
Note : Fill up where applicable
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 26 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 5 of 5
1. Servolifter
- Check oil condition and any leakage
- Check linkage split-pin and conduit condition A-Frame Good( ) / Not Good( )
- Check rubber bumper
Note : Fill up where applicable
2. Limit Switch
- Check condition and functionality All limit switches Good( ) / Not Good( )
Note : Fill up where applicable
4. Power pack
- Check oil condition and any leakage A-Frame Good( ) / Not Good( )
Note : Fill up where applicable
5. Plunger
- Check plunger and spring condition A-Frame Good( ) / Not Good( )
Note : Fill up where applicable
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 27 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 1 of 3
4. Backreach
- Check functionality and condition Backreach Good( ) / Not Good( )
- Check wire termination Multi-functional platform Good( ) / Not Good( )
Note : Fill up where applicable
5. Portal beam
- Check functionality and condition Right hand side Good( ) / Not Good( )
- Check wire termination Left hand side Good( ) / Not Good( )
Note : Fill up where applicable
4. Indicator light
- Check functionality and condition All location Good( ) / Not Good( )
- Check wire termination
6. Foot siren
- Check functionality and condition Siren Good( ) / Not Good( )
- Check wire termination
9. Operator seat
- Check functionality and condition Operator seat Good( ) / Not Good( )
1. Compressor
- Check structure and condition Control room Good( ) / Not Good( )
- Check wire termination and functionality Operator cabin Good( ) / Not Good( )
- Check gas quantity and any leakage Checker cabin Good( ) / Not Good( )
Note : Fill up where applicable
2. Indoor unit
- Check structure and condition Control room Good( ) / Not Good( )
- Check wire termination and functionality Operator cabin Good( ) / Not Good( )
Note : Fill up where applicable Checker cabin Good( ) / Not Good( )
4. Mechanical part
- Check blower motor mounting condition All location Good( ) / Not Good( )
- Check belting condition
- Check cleanliness
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 30 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
1. Trolley system
- Pump-in new grease into greasing point Trolley sheave Done( ) / Not Done( )
Note : Fill up where applicable Trolley floating shaft Done( ) / Not Done( )
Trolley plumber block Done( ) / Not Done( )
Catenary wheel Done( ) / Not Done( )
Catenary sheave Done( ) / Not Done( )
Catenary McGill guide roller Done( ) / Not Done( )
Backreach-catenary sheave Done( ) / Not Done( )
Backreach rope tensioner bearing Done( ) / Not Done( )
1. Boom system
- Pump-in new grease into greasing point Boom drum Done( ) / Not Done( )
Note : Fill up where applicable
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 31 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 1 of 3
1. Guide rail
- Check buffer spring and rail condition All location Good( ) / Not Good( )
- Check mounting condition
2. Gear
- Check rack and pinion gear condition All location Good( ) / Not Good( )
4. Motor
- Check casing and mounting condition Top of cabin Good( ) / Not Good( )
5. Brake
- Check functionality and brake condition All brakes Good( ) / Not Good( )
6. Cabin level
- Check setting on each floor level All floors Good( ) / Not Good( )
7. Push button
- Check functionality and condition All push buttons Good( ) / Not Good( )
8. Cable
- Check cable insulation and condition Power cable Good( ) / Not Good( )
- Check protection rubber and mounting condition
9. Carrier structure
- Check door and roof door condition Carrier Good( ) / Not Good( )
- Check ladder condition
10. Intercomm
- Check condition and functionality Inside carrier Good( ) / Not Good( )
1. Electrical part
- Check AC power LED light up Machinery house
- Determine standby battery condition ( 25.5 ≤ x ≤ 26.6 Vdc ) - Zone 1 Good( ) / Not Good( )
- Check any alarm LED light up from panel - Zone 2 Good( ) / Not Good( )
- Fire, Fault, Off, Extinguisher release, Walk test, External - Zone 3 Good( ) / Not Good( )
acoustic alarm off, CPU fault, Power supply fault. - Zone 4 Good( ) / Not Good( )
- Any fault message on the display (Stated the fault message) - Main Good( ) / Not Good( )
Note : Fill up where applicable - Charger Good( ) / Not Good( )
- Evacuate Good( ) / Not Good( )
2. Mechanical Part
- Visual Check for cylinder pressure gauge reading
(±170 bar for 225 bar system) Good( ) / Not Good( )
- Examine cylinder valve and hoses for sign of damage,
wear or leakage Good( ) / Not Good( )
- Inspect all piping & nozzles for any sign damage & leakage Good( ) / Not Good( )
Note : Fill up where applicable
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 32 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 2 of 3
2. Control console
- Check functionality and condition Machinery house Good( ) / Not Good( )
- Check structure
3. Structure
- Check structure condition Rubber buffer Good( ) / Not Good( )
- Check hook and latch condition Hook block Good( ) / Not Good( )
5. Electrical part
- Check wire termination and contactor condition Electrical box Good( ) / Not Good( )
1. Compressor
- Check oil level sufficient, air filter, V-belt, pressure gauge, Machinery house Good( ) / Not Good( )
safety valve, piping and mounting condition
- Check any abnormal sound or vibration
2. Pressure Switch
- Check pressure setting Machinery house Good( ) / Not Good( )
Note : Cut in: 9.9 kg/cm2 & Cut out: 8.0 kg/cm2
- Adjusting screw locknut and check wire termination
3. Motor
- Check mounting and any abnormal sound Machinery house Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 33 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 3 of 3
2. Check lighting condition and functionality Cabin ceiling Good( ) / Not Good( )
3. Intercomm
- Check condition and functionality Good( ) / Not Good( )
4. Structure
- Check mounting and condition All location Good( ) / Not Good( )
- Check door and glass
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 34 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM: Page 1 of 1
1. Bushing
- Check abnormal sound and vibration All location Good( ) / Not Good( )
3. Rest support
- Check forestay rest support condition All supports Good( ) / Not Good( )
4. Boom buffer
- Check condition and mounting A-Frame Good( ) / Not Good( )
3. Structure
- Check mounting and condition All sheaves Good( ) / Not Good( )
1. Indicator bulb
- Check condition and functionality All indicators bulbs Good( ) / Not Good( )
2. Check lighting condition and functionality Cabin ceiling Good( ) / Not Good( )
3. Structure
- Check mounting and condition All location Good( ) / Not Good( )
- Check door and glass
4. Intercomm
- Check condition and functionality Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 35 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
1. Gantry system
- Pump-in new grease into greasing point All boggies Done( ) / Not Done( )
1. Boom system
- Pump-in new grease into greasing point All boom sheaves Done( ) / Not Done( )
1. Motor
- Check mounting and condition Main cable reel motor Good( ) / Not Good( )
2. Main cable
- Check cable condition Main power cable Good( ) / Not Good( )
3. Structure
- Check mounting and condition All mounting Good( ) / Not Good( )
4. Slip ring
- Check slip rings condition Good( ) / Not Good( )
5. Gearbox
- Check gearbox oil condition Good( ) / Not Good( )
- Check mounting and condition Good( ) / Not Good( )
- Check any abnormal sound Good( ) / Not Good( )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 37 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
1. Boom backstay
- Pump-in new grease into greasing point All greasing points Done( ) / Not Done( )
Note : Fill up where applicable
1. KBT coupling
- Pump-in new grease into greasing point Done( ) / Not Done( )
Note : Fill up where applicable
Please see attachment (No. : )
General Remark :
Document No. FM-M&R-QC002-000
Revision No. 000
Effective Date 15-Apr-10
SUPPORTING DOCUMENT Page 38 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AC/DC MEGGER : Page 1 of 1
General Remark :