Training For KOJA RTG

Training
g
Instructions
For KOJA RTG
ZPMC
CHAPTER 1
General features of RTG Cranes

● Supported on 8 rubber-
rubber-tyred wheels
● Powered with a diesel-

diesel-alternator set & lithium
battery pack which supply power to every
movement drive
● Equipped with a telescopic spreader which is able

to handle 20', 40', 45' standard containers
CHAPTER 1
● Provided with a swayy damping
p g device to reduce
spreader sway and increase productivity
● Spreader slewing device for easier spotting of the

container
● A 90
90--degree,
g 360
360--degree
g wheel turning
g system
y
allows ease of movement
CHAPTER 1
●Dimensions
pass across 6 rows of containers p

p plus one truck way
y
(6+1 lane)
pass over five containers 9' 6" high with one 9’6”
container lifted under the spreader(1
p ( over 5))
CHAPTER 1
●Structures
Gantryy frame: box-

box-section welded construction
Trolleyy rail: clipped

pp on the upper
pp g girder
Equalizer
q beam: hinged
g to the sill beam by
yppin
Each equalizer
q beam has two bogie
g trucks and four
wheels
CHAPTER 1
●Main hoist
Constant p
power control
Speed
p is automatically
y adjusted
j depending
p g on the
load being lifted
Over load protection device
Over speed protection

CHAPTER 1
● Ope
perator's
a o s cab located
oca ed u
under
de the
e trolley
o ey
frame
● One set of trolley driving device on the

t ll fframe
trolley
CHAPTER 1
● Protection for safety
Overload protection
Di
Diesel l engine
i over speed d protection,
t ti hi
high
h water
t
temperature and low oil (lubrication) pressure
signaling
Anemometer
Anti--collision devices for gantry traveling
Anti
Emergency stop buttons
Spreader
p load indicator , lock/unlock indicator
Limit switches for every movement and signal
indicators, etc.
CHAPTER 1
● Ot
Other
e equ
equipment
p e t
Lighting and signaling for operation at night
Al
Alarms ffor gantry
t traveling
t li
Telephones
Radio speakerphone
1.1 General layout of RTG
Figure 1.2
1.2--1 RTG Crane general layout
Figure 1.2-
1.2-2 RTG crane trolley layout
As shown in Figure 1.2-

1.2-1 and 1
1--2.2, the main
composition of crane is as follow:
1-Gantry frame steel structure
2-Stairs,
2 Stairs, platform and ladder
3-Electrical house
4-Gantry
4 Gantry traveling mechanism
5-RTG tyre pressure monitoring system
6-Festoon
6 Festoon cable system
7-Trolley travel L.S.
8 Sp eade
8-Spreader
9-Headblock
10- Power unit
11-Main hoist mechanism

12-Trolley
12 Trolley travel mechanism
13-Antisway device
14-Operator’s
14 Operator s Cabin
15-Horizontal wheel system
16-Trolley
16 Trolley anchor device
17-Spreader skew device
18-Hoist
18 Hoist over travel L.S.
1.2 Principal Technical Parameters of RTG
Description Value Unit Remarks
Rated
a ed lifting
g capac
capacity
y Under
U de sp
spreader
eade 41 Te
e
Lifting height Under spreader 18.2 m
Hoisting
H i ti speed
d with
ith 35t lload
d 22 m/min
/ i
empty spreader 55 m/min
Gantry travel speed empty spreader 90 m/min
Trolley
y travel speed
p 70 m/min
Span 22.71 m
Wh l b
Wheel base 79
7.9 m
Number of wheels/No. of driving wheels 8/4 pieces

1.2 Principal Technical Parameters of RTG
D
Description
i ti V l
Value Unit
U it R
Remarks
k
Spreader slewing ±5 Degree
Di
Diesel
l M d l
Model 6LTAA8 9 G2
6LTAA8.9-G2 Cummins
C i
engine China
Power 220 BKw
Revolutions 1500 rpm
Alternator Model MP-220-4A Marathon
Shanghai
Power 275 KVA 440V,50HZ
Lithium Battery Pack 16 Li-lon Battery Module Sumitomo
Package
Number of containers 6 Container
stacked by the Crane
Number of containers the 5 Container
Crane passes over
1.3 Steel Structure part
1.4 General
● Welded steel structures always

y contain
undetectable cracks.
● The cracks grow when subjected to fluctuating

stresses beyond
y a veryy small value.
● Fatigue
g crack will lead structure disabled and out
of service
● Periodic inspection is required to detect fatigue to

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

welds
● UT shall be used at the critical locations of butt
welds
1.4.1
1 4 1 Test procedure
●Visual Testing
The surface should be free of dirt and grease. Cracked paint
surface.
●Magnetic Particle Testing

The test surface must be free of loose rust and moisture. If
required, clean painted surfaces with power tools by
grinding, or needle scaling. An electromagnetic device,
such as a yoke, may be used to a magnetic field.
●Ultrasonic Testing
Testing should be done in accordance with approved method
and
a d tthe
e requirements
equ e e ts sshown
o in "INSPECTION"
S C O
1.4.2
1 4 2 Inspection
(1) All bolted and welded joints shall be visually

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

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

AWS D1.1
D1 1-96
96, including Section 5
5. "Inspection"
Inspection ,
and all provisions applicable to cyclically loaded
structures.
1.4.2
1 4 2 Inspection
(5) Required inspection is shown on the attached

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

only, the inspector shall inspect the weld form both
sides
id unless
l otherwise
th i notedt d.
(7) Inspection of bolts shall comply with AISC

Specification for Structural Joints Using (CHINA)
GB1228-94
GB1228 94 10
10.99 GRADE bolts (equivalent to ASTM
A490 Bolts, latest edition).
1.4.3
1 4 3 Reporting procedure
All indications of defects should be shown on the

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

propagating into the base metal, etc
1.4.3
1 4 3 Reporting procedure
((4)) Defect location: right-hand

g side, left-hand side,
which box section, crane leg number, waterside,
landside, distance in inches to nearest station, etc.
((5)) Method of testing:

g VT, MT, and UT.
((6)) Inspector's
p comments and signature
g
1.4.4
1 4 4 Inspection period
((1)) Initial inspection:

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

manual three months before the end of the
warranty period. Inspect six year points and others
as designated
g byy the p
port.
((3)) Maintenance inspection

p as shown in manual
1.4.5
1 4 5 Typical repair procedure
(1) Work shall be conform to the requirements for

Structural Steel Buildings, Allowable Stress Design,
ninth or latest edition, including current supplements,
and AWS Structural Welding Code, D1.1-96,or latest
edition, including all provisions applicable to cyclically
l d d structures
loaded t t and
d Section
S ti 8, 8 "Strengthening
"St th i and d
Repairing Existing Structures“
(2) All temporary attachments shall be removed after
completion of work. Removed weld area shall be
ground smooth and a prime paint coat applied to the
surface.
((3)) All repaired
p jjoints exposed
p to weather shall be seal
welded.
1.4.5
1 4 5 Typical repair procedure
(4) Welders and welding operators shall have current

AWS certificates for the materials and processes being
used.
(5) Weld procedures shall be qualified in accordance with
AWS D1.1-96 or latest edition.
(6) The
Th Port
P t may performf NDT ttesting
ti off th
the Contractor's
C t t '
work .
(7) All areas where paint has been removed
removed, or damaged
damaged,
shall be restored to its original condition in accordance
with the original crane specifications
specifications.
(8) Re-tightening of bolts after inspection shall be
accordingg to relative standard.
1.5 Mechanical device part
1.5.1 Gantry traveling mechanism

1.5.1.1 Composition of gantry traveling mechanism
● Eight rubber inflated tyres

Four are drive and laid on each corner of the
crane;Four are idle.
● Four set of electric screw pusher device system for
wheel--turning.
wheel
90°
Each tyre can be rotated about its center by 90°
&16°
&16 °
● The bogie and equalizer beam connect by skew
b i
bearing
● Four vertical flange-
flange-mounted motors with brakes
● Four
F gear reducers
d t drive
to d i th
the chain
h i wheel
h l and
d
chain
● Safety device
1.5.1.2 Table of Gantry Traveling Particulars
Gantry travel Only spreader 90 m/min
speed
p With rated load 25 m/min
A.C. motor Model MVK8186D-FK FUJI
((with brake)) o e
Power 22 kw
Qty. 4
Reducer Model FVS370.30.D1B ZPMC
Reduction ratio 30.61
Input power 22 kw
Qty. 4
Rubber tyres Model 21.00-25,40ply ZPMC Samson
Diameter 1550 mm
Inflation
f pressure 980 kPa 144psi
Qty 4/8 (driving/total)
1.5.1.3 Points for Attention in Operation
After a long term of non-operation

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

the reducers, bearings, etc. to be lubricated fully
and carefully observed
observed, and then operation with
a load can be started.
1.5.1.4 Inspection items and period for maintenance
((1)) Oil (g
(grease)) supply
pp y
During
g oil (g
(grease)) replacement
p the old oil (g
(grease))
shall be discharged thoroughly. Generally speaking
the lubricant shall not be mixed, especially
p y the
grease. Mixed grease may result in blockage and
bearingg damage.
g
Check whether lubrication is correct. Lubricate in

accordance with lubrication schedule .
Period: routine
((2)) Loosening
g of securing
g bolts:
All p
parts and components
p
Attention shall frequently be paid to loosening of the
bolts, p
particularly
y after the first week of crane
running and then once per month check all the bolts
and re-tighten
g them.
Special attention shall be paid to those bolts which
contribute to fastening g but are easily
y neglected.
g
Period: routine and once per month

((3)) Motors :
Check temperature
p rise for any
y abnormal condition
Check for any abnormal heating in the bearings
Check for anyy abnormal noise in the motor
Period: routine
(4) Reducer:
Check whether oil level is adequate.

Check for oil leakage.
Ch k ffor abnormal
Check b l ttemperature
t rise.If
i If the
th casing
i
temperature is higher than the ambient temperature by
more than 45°C
45°C, the inner part shall be inspected
inspected.
Check for abnormal noise in the internal part and
disassemble and inspect if there is any any.
Check for loosening of connection bolts .
Period: routine.
For detail,, please
p refer to the “Instructions of reducers”.
((5)) tyre
y :
Check that everyy tyre

y is inflated sufficiently.
y The right
g
tyre pressure shall be 980kPa(144psi). The normal
pressure ensure that the longer
p g life of tyre.
y
Period: routine
((6)) Slew bearing:

g
● Bolt Inspection:
p
When the slewing bearing works continuously for
about 100 hours after installation, the installation
bolts must be inspected fully for their preload. The
preload must meet the requirements.
p q And the
installation bolts must be inspected after
continuously y working
g for 500 hours.
(6) Slew bearing:
● Greasing:
G i Th
The raceway off the
th slewing
l i b bearing
i mustt b be
greased at regular intervals. Generally, if the rolling
elements of the slewing bearing are sphere shaped
shaped, the
raceway must be greased after working for 100 hours;
For high temperature and dusty working environment
environment,
greasing interval must be shorter. And also if the
bearing works continuously for a long period, it must be
greased. The slewing bearing must be 100% greased
at each time.
For detail,, please

p refer to “gantry
g y slew
bearing manual”.
((7)) Electric screw p

pusher for rotating
g:
For detail, please refer to “Electric screw
pusher manual”
manual
1.5.1.5 How to replace gantry tyre
The following works are based on the safety rules.
● Gantrytyre replacement shall be carried out in

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

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

such as various replacement parts(new tyre etc.) and
required tools(two hydraulic jacks, electrical impact
wrenchh etc.
t ) putt att hand
h d
(2) The working area shall be clear and enclosed with

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

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

be replace under the reduce pedestal of the other
wheel that is not to be replaced and fitted under the
same equalizerli b
beam withith th
the wheel
h l tto b
be replaced
l d ((or
lift the jacking support frame) to enable the wheel to be
lifted off the ground and then the wheel may be
removed and replaced.
(5)Dismantle the bolts connecting between the rim and

drive/driven axle,, take out the tyre
y and rim from the
driving/driven axle.
(6) Before dismantle the tyre from the rim, deflate the tyre
completely,
p y, and then take out the lock ring,
g, bead seat
band, side ring and O ring, finally the tyre.
Figure1.5.1.5- 2 Tyre rim
1.5.1.5
1 5 1 5 How to replace gantry tyre
(7) Install the new tyre onto the rim

rim, then install O ring
(to ensure seal effect, use a new O ring), side ring,
bead seat band and lock ring
ring.
(8) Inflate the tyre to the specified pressure

pressure. Before
inflation, make sure the O ring and lock ring are
installed properly; especially the lock ring shall be
correctly installed.
(9) Install the tyre and rim onto the drive/driven axle.
Fasten the connecting bolts and nuts, the fasten
torque shall be at rated torque.
(10) releasing jacking up system, clear the working

area, running the gantry slowly, keep observing the
new tyre until every thing is OK.
1.5.2 Main hoist mechanism
1.5.2.1 Composition of main hoist mechanism
● One motor
● One g gear reducer
● One low speed gear coupling
● One drum
● One high speed flexible coupling
● Two high speed brakes
● Tachometer,, over speed
p protection,
p , cam
limit protection
1.5.2.1 Composition of main hoist mechanism
● Over speed
p p
protection device located at the rear p
part
of the motor.
Stop
p main hoist when the motor speed
p reaches 115% of
its rated speed
●Cam limit protection is fitted at the end of the drum.

provides
p o des tthe
e following
o o gp protection:
otect o
Stopping at upper lift end and lift lower end
Slowing down before reaching upper and lower lift ends
Stopping at lift upper extreme limit end
1.5.2.2 Table of Main Hoist Particulars
Num. of wire ropes on the drum 4 pcs
M lti l off rope reeving
Multiple i 2
Lifting capacity (under spreader) 41 Te
Hoisting with 35t load 22 m/min
speed empty spreader 55 m/min
Linear velocity with full load 44 m/min
of empty spreader 110 m/min
wire rope
The drum Nominal 980 mm
diameter
Num of groups
Num. 4
of grooves
Number of 3 pcs
wraps of rope
1.5.2.2 Table of Main Hoist Particulars
Motor Model MVK931PB FUJI
Power 150 Kw
Revolutions 726/1814 rpm
Qty.
Q y 1
Reducer Model FH1210.51.C2A ZPMC
Qty. 1
High Speed Model YP31-
YP31-560x30
560x30--Ed1250
Ed1250--60 ZPMC
B k
Brake Model of thruster ED1250
ED1250--60 ZPMC
Braking torque 3550 Nm each brake
Qty. 2
Wire rope Model IWRC 6xFi(29)
6xFi(29)--25
25--B KISWIRE
Diameter Ø25
1 5 2 3 Main hoist wire rope reeving and its application
1.5.2.3
● Four
F maini h
hoist
i t wire
i ropes on d drum
● Each rope has 6 wire clamps on drum
● Wire clamps’ screw bar and nut are M24
●The middle two main hoist wire ropes go
downward to the headlock’s sheaves and go
back to trolley, fixed on the slewing device
●The two side main hoist wire ropes go to the
other side of trolley, the go downward to the
headlock’s sheaves and go back to trolley
trolley, fixed
on the slewing device
1.5.2.3 Main hoist wire rope
p reeving
g and its application
pp
How to adjust tension for four rope
◆ The four wire rope must be tensioned equally for

spreader at correct position and avoid slewing
◆ If uneven tension between them is found
found, the
end securing clamps may be loosened and
tightened up or release the appropriate rope
◆ Or simply adjust the screw at slewing
mechanism to vary the rope lengths accordingly
to make tensions between the ropes even
1.5.2.3 Main hoist wire rope reeving and its application
How to adjust tension for four rope
◆ After the first p

period of crane running,
g, the
ropes must be re-re-adjusted depending on their
stretch
◆ In normal operation uneven tension between
the four sets of wire ropes shall be corrected
immediately once it is found
● Attention shall frequently be paid to the fastening

condition of the wire
ire rope clamps and tighten
them if loosened
● Frequently
F tl check
h kb bolts
lt off th
the clamps
l and
d replace
l
them immediately if thread damage, cracks, etc.
are found
● The ropes shall not be twisted or knotted during
reeving
● Pay attention to inspection for the rope jumping
out of the sheave groove
● If there is any interference of the wire rope with
other mechanical or structural parts
● The wire ropes shall frequently be checked

during application and shall be replaced if
▲ wires damaged account for 1/10 the wire in the
whole strand
▲ the diameter of the wire rope is reduced by 7% of
its nominal size due to surface wear
1.5.2.4 Points for Attention during Operation
After a long term of non-

non-operation of the Crane
or after disassembly and re-
re-assembly
The crane shall be run first without load

enabling
bli the
h reducers,
d b
bearings,
i etc. to b
be
lubricated sufficiently and operation with load
can be
b started
d onlyl iit iis confirmed
fi d that
h the
h
running condition is normal.
1.5.2.5 Inspection Items and Periods for Maintenance
(1) Oil (grease) supply
When the oil (grease) is to be replaced the old

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

Lubrication should be done in accordance with
Lubrication Schedule.
(2) All parts

t and
d components
t
● Check for loosening of fastening bolts
Frequently check for bolt loosening, especially

one week after the Crane’s first runningg and
then once per month all the bolts shall be
inspected and re-
re-tightened. Special
attention should be paid to those bolts which
contribute to securing but is easily neglected
Maintenance period: routine and once per month
(3) El
Electrical
ti lM Motors
t
● Check temperature rise and overheating.

● Check whether the bearing is abnormally
heated.
● Check for abnormal noise inside the motor
motor.
Maintenance period: routine

(4) G
Gear reducer
d
● Check that the oil is adequate by using the oil

level indicator.
● Check for oil leakage.
● Check if is there any abnormal temperature
。
rise? If the temperature is more than 45 C
above the ambient temperature
temperature, the internal
portion should be inspected.
(4) G
Gear reducer
d
● Check for abnormal noise inside the

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

“Instructions of the reducer”
(5) Coupling
● Check whether the bolts are loosened
loosened. Period:
routine
● Check eccentricity and end runrun--out of the two
halves of coupling. Normally check once per
year.
year
● Insure normal lubrication for the drum coupling.
P i d routine
Period: ti
For detail,
detail please refer to the “DC
DC
series hoist drum coupling manual”
and “A315
A315 coupling manual”
manual
(6) D
Drum
● Check for loosening of the securing bolts.

Period: routine
● Check
Ch k whether
h th wear off ththe rope grooves
exceeds limit value which is generally
20% wire
i rope didiameter.
t
Period: once per month
(7) Anti-
Anti-friction bearing (rolling bearing)
45°C (in
● Temperature rise shall not exceed 45°
comparison
i with
i h ambient
bi temperature).
)
● Check for abnormal noise.
Period: routine
● Check for loosening of connection bolts.

P i d routine
Period: ti
(8) E
Encoder
d
● Check whether the transmission is in good

condition
Period: routine
(9) B
Brake
k di
disc
● Check the disc surface for unevenness (convex-
(convex-concave)
which should not exceed 00.3mm,
3mm and correct if necessary
necessary.
Period: once a month
● Check whether wear exceeds limit and replace the disc when
wear exceeds 20% of thickness.
Period: once p per month
● Check whether temperature rise is abnormal on surface.
Period: routine
● Check whether the disc surface is damaged or contaminated
with oil (grease).
P i d routine
Period: ti
● Check for fine cracks.
Period: routine
(10) B
Brake
k
● Check that the brake action is maneuverable
● Check
Ch k wear off the
th bbrake.
k
The limit value is 3mm and replace if the limit is exceeded.
Clearance at the brake shoe shall be kept to 0 0.5
5 -1.5mm.
1 5mm
Every pivot pin shall be frequently greased. Frequently check wear
of the p
pin and matched fore.
Period: routine
● Check the pulse signal transmitter for height indication
● Check that gearing is in good condition
● Check that pulse signal transmission is correct.
Period: routine
For detail,
detail please refer the manual from
ZPMC FENGCHENG
1.5.2.6 How to replace
p hoist wire rope
p

1.5.2.6 How to replace hoist wire rope
● Hoist
H i t wire
i rope replacement
l t shall
h ll b
be carried
i d outt
in no
no--wind weather condition
● Consider the following g basic steps

p to accomplish
p
the replacement:
(1) Before replacement
replacement, preparation work shall be
done such as various replacement parts(new
wire rope etc
etc.)) and required tools put at hand
hand.
(2) The working area shall be clear and enclosed
with warning line and caution
caution.
(3) Fi
First,
t cutt the
th new ropes as which
hi h llength
th and
d
quantity according to the drawing’s requirement
andd th
then complete
l t th
the pressedd rope connector.
t
Otherwise, prepare some jute ropes which
di
diametert about
b t 20mm
20 andd wires
i for
f binding.
bi di
(4) To lower the spreader onto the ground and

make it steady,y, then looseningg the wire ropes
p
slowly until they lay on the headblock steadily
and loosening g continued until that wire ropes
p
remained on the drum approach the fixed bolt.
When the wire ropes p loosened completely,
p y shut
down the diesel generator set.
(5) Bi
Binding
di th the 4 old
ld wire
i ropes which
hi h wind
i d on th
the
drum with jute ropes, then remove the fixed bolt
andd ttake
k off
ff the
th wire
i ropes which
hi h remained
i d on
the drum carefully. Then pulling the jute rope let
th old
the ld wire
i rope ffalling
lli d
down tto th
the grounddbby
gravity.
((6)) Take the 4 old wire ropes

p connector which
connected to the lever of the skewing system
binding
g with jjute ropes.
p Take out the old
connector, lower the rope to the ground.
(7) U
Using
i jjute
t ropes reeve th through h th
the sheaves
h
according to the rope reeving system drawing
andd bi
binding
di withith th
the 4 endd off th
the new wire
i
ropes, pulling them up to the trolley and winding
th wire
the i ropes onto t the
th drum
d b
by 3 circles,
i l th
then
fastening that ropes with bolts primary.
((8)) Other 4 wire rope

p connectors binding g with jjute
ropes and pulling them up to the trolley in place
then insert the jjoint p
pin.
(9) Aft
After wire
i ropes replacement
l t are completed,
l t d
start the diesel generator set, switch on the
power source, raise
i th the spreader
d above
b th
the
ground about 300mm. Observe the wire ropes
slack
l k and d th
the h
headblock
dbl k d deflection
fl ti iin llevel.l
Adjust the ropes slack by loosen the bolt which
fi d th
fixed the ropes endsd on th the d
drum, and d ttension
i
the slack rope, then fasten the bolt and cutoff
th unwanted
the t d partt off the
th rope.
DANGER! THE PERSON ON THE GROUND

SHALL PREVENT FROM HITTING BY WIRE
ROPE FALLING DOWN.
DOWN
DANGER! WHEN THE HOISTING/LOWERING
IS RUNNING
RUNNING, KEEP AWAY FROM THE HOIST
MECHANISM; DO NOT TOUCH ANY
ROTATING COMPONENTS
COMPONENTS. ALL THE
PERSON ON THE TROLLEY SHALL BE
PROVIDED WITH SAFE BELT
BELT.
153H
1.5.3 Hoist
i t over ttravell L
L.S.
S
1.5.3.1 Composition of hoist over travel L.S.
● Location: On the antisway platform

● Consists of ggravity
y type
yp L.S.,, wire rope,p , strike circle
etc.
● For emergency, if the hoist motion failed to stop at
rated hoist height, the strike circle will touch the top
surface of spreader, the over travel L.S. will act
i
immediately,
di t l th
the hhoist
i t motion
ti willill b
be stopped.
t d
● Check bolts for loosening
P i d routine
Period: ti
● Check the function of the L.S.
P i d routine
Period: ti
1.5.4 Trolley
y traveling
g mechanism
1.5.4.1 Composition of trolley traveling mechanism
● One (1) electric motor which the drive

reducer through the coupling
● The reducer in turn drives the pinions

through universal shafts to travel on the
rack and propel the trolley along the rail
● The wheel system consists of wheels,

wheel shafts supports, bearings, etc.
1.5.4.1 Composition of trolley traveling mechanism
1.5.4.2 Table of Trolley Traversing Particulars
Description Value Unit Remark

Traversing Speed 70 m/min
Motor Model MVK8186B FUJI
(with brake) Power 25 Kw
Revolutions 1700 Rpm
Qty. 1 Set
Brake Model YP11
YP11--ED220
ED220--50
50-- ZPMC
315x20--IA
315x20
Model of thruster ED220--50
ED220 ZPMC
Rated Braking torque 260 Nm
Setting Braking torque 220 Nm
Qty. 1 Set
1.5.4.2 Table of Trolley Traversing Particulars
Description Value Unit Remark

Traversing Speed 70 m/min
Reducer Model FH550.26.A2A ZPMC
Input Power 25 Kw
Qty. 1
Wh l
Wheels Di
Diameter 500
00 mm
Qty. 4
T ll R
Trolley Railil 80 80
80x80 square bar
b
with bottom
plate
1.5.4.3 Points for Attention During
g Operation
p
(1) To ensure normal operation of the trolley
and reduce shock, careful inspection is
needed
(2) Check that the noise in the reducer is

normal the bearing is not overheated,
normal, overheated and
that the oil level is correct.
correct.
Iff any off these problems appear, the crane
should be stopped immediately and the
problem
bl corrected.
corrected d.
1.5.4.3 Points for Attention During Operation
(3) Periodically check that the attachment of the wheel

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

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

p
protection.
● Both (forward and backward) end extreme limit
p
protection.
● Both (forward and backward) end slow down.
● Trolley anchoring limit protection
protection.
● Cabin platform gate open protection
● Hydraulic buffers are fitted at both ends of the
girders to protect the trolley in case of failure of
all the end protection and end extreme limit
protection.
1.5.4.5 Points for Attention during
g trolley
y operation
p
(1) In case of abnormal noise during traversing it is

necessary to check if the horizontal wheels are
loosened or dropped, etc.
After the above causes are removed,
removed if abnormal noise
still occurs the reason may be binding the rail or friction
between the rail and rail support
pp beam. In this case
add a little oil (grease) where the noise occurs.
(2) Each time after operation has been completed the
operator shall position the trolley at the parking location
and anchor it using the anchoring device to prevent the
trolley from moving along the rail due to wind gust or
other causes. Each time before operation the anchor
must be released.
1.5.4.5 Points for Attention during trolley operation
(3) Normally the trolley forward and backward end extreme

limits are not activated, and if they are activated the
causes shall be found out and removed. They shall be
periodically checked and maintained.
(4) P
Pay special
i l attention
i to the
h nuts on the
h screw llever on
the bumper support and check them once per shift and
tighten them if loosened.
loosened
(5) Check carefully the operator's cab suspension support,
operation condition of the wheels and the rail track for
abnormal matter and the connection welds and bolts
on the cab support
(6) Periodically grease every lubrication point to ensure
normal lubrication.
1.5.4.5 Points for Attention during trolley operation
(7) For motors, reducers, couplings, etc.

maintenance shall be the same as that for the
main hoist
For coupling detail, please refer “ZPMC

coupling manual”.
manual .
For reducer detail, please refer to”
Instructions of reducer”.
For brake detail,
detail please refer to the
manual of ZPMC FENGCHENG
1.5.4.6 How to replace trolley wheel and axle
Trolley wheel and axle replacement shall be carried out in

no--wind weather condition.
no
Consider the following basic steps to accomplish the
replacement:
(1) Before replacement, preparation work shall be done
such as various replacement parts (new wheel and
axle
l etc.)
t ) and
d required
i d ttools
l (h
(hydraulic
d li jjacks,
k electrical
l ti l
impact wrench, mobile crane etc.) put at hand.
(2) The
Th working
ki area shall
h ll b
be clear
l andd enclosed
l d with
ith
warning line and caution.
(3) The crane is at non working condition and stay at a

level ground
ground, the trolley shall be parked and
girder，lower the
anchored at the middle of the girder，
spreader and headblock onto the ground.
(4) If the replaced trolley wheel is at horizontal wheel
side dismantle the horizontal wheel and its bracket
side,
first; and if the replaced trolley wheel is at non
horizontal wheel side,, dismantle the plate
p in front of
the trolley (at the end of the trolley frame). See figure
1.5.4.6--1.
1.5.4.6
Figure
gu e 1.5.4.6-
1.5.4.6
5 6 -1
(5) Dismantle the connecting bolt between the wheel

assembly and trolley frame as show in figure 1.5.4.6-
1.5.4.6
1 5 4 6-1,
1
totally 4 no. of M24 bolts.
(6) Put one hydraulic jack(rated at 16T) under the jack up
pad as show in figure 1.5.4.6-
1.5.4.6-2(it is better to put a
hardwood pad under the hydraulic jack to decentralize
the pressure on the girder), jacking up about 170mm,
and then rolling
g the wheel assembly y along
g the trolley
y
rail until come out of the trolley frame.
((7)) Use mobile crane to lower the wheel assemblyy down to
the ground. The total weight of wheel assembly is
about 280kg.
Figure 1.5.4.6
1.5.4.6--2
DANGER WITH JACKING DEVICE!

MAKE SURE THAT THE HYDRAULIC
JACK IS NOT LEAKING AND IS NOT
LOWERING PRESSURE !
DANGER! HOLD THE WHEEL
ASSEMBLY CAREFULLY, PREVENT
FROM FALLING DOWN TO THE
GROUND.
(8) Dismantle the wheel assembly, replace the old wheel

and axle with new one
one, reassembly the wheel
assembly as per figure 1.5.4.6-
1.5.4.6-3.
Figure 1.5.4.6
1.5.4.6--3
(9) Use
U mobile bil crane tto hhoist
i t th
the wheel
h l assembly
bl b
back
k tto
the girder, rolling the wheel assembly along the
trolley rail back to the original position
position.
(10) Lower the hydraulic jack slowly; make sure the
wheel assembly aligns with the mounted plate of the
trolley frame.
(11) Fasten the connecting bolts between wheel
assembly and trolley frame as shown in figure
2.5.4.6--1.
2.5.4.6
(12) Make sure all bolts are fastened to the specified
torque.
q Clear the ggirder and trolley
y area.
(13) Running the trolley slowly, keep observing the new
wheel until every thing is OK.
1.5.4.6 How to replace
p trolley
y wheel and axle
DANGER! THE PERSON ON THE GROUND

SHALL PREVENT FROM HITTING BY THE
COMPONENTS FALLING DOWN.
DOWN
DANGER! WHEN THE TROLLEY IS
RUNNING KEEP AWAY FROM THE TROLLEY
RUNNING,
MECHANISM; DO NOT TOUCH ANY
ROTATING COMPONENTS
COMPONENTS. ALL OF THE
PERSON ON THE TROLLEY SHALL BE
PROVIDED WITH SAFE BELT
BELT.
1.5.5 Horizontal wheel system
1.5.5.1 Composition of horizontal wheel system
● Consists of supports, eccentric shafts, horizontal

wheels, bearings and seals etc.
● Two complete sets, fitted on horizontal wheel
bracket.
● Consists of supports, eccentric shafts,

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

sets fitted on horizontal
wheel bracket.
● Horizontal wheels contact the side surface

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

horizontal wheel and the rail side surface
should be not less than 3mm.
● After a certain time of running the

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

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

loosening and tightened
● If abnormal noise is found during trolley

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

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

Period routine
1.5.6 Spreader skewing device
1.5.6.1 Composition of skewing device and its function
● Consist of an eelectrical
lectrical pusher of XDT5000
500--23, lever system, etc .
500
● The spreader is skewed horizontally by the
forward and backward movement of the
thruster.
● The spreader can be skewed on the
horizontal plane by ± 5°at 4m above the
ground
● Different maximum angles depending on its
lif d h
lifted height
i h
1.5.6.2 Inspection Items and Period for Maintenance

During oil (grease) replacement the old oil (grease)
shall
h ll bbe di
discharged
h d th
thoroughly.
hl G Grease shall
h ll nott
be mixed because mixed grease may result in
bearing g damageg
Period: routine
(2) All parts and components

Check bolts for loosening
Check that lubrication is correct .
L brication shall be done in accordance with
Lubrication ith the
lubrication schedule.
Period: routine
1.5.6.2 Inspection Items and Period for Maintenance
(3) Sh
Sheaves
Check whether the sheave bearing is overheated. It is
necessary tot iinspectt th
the inner
i partt if the
th
temperature of the casing is higher than the
ambient temperature by 45° 45°C.
C
Check whether bolts on the hollow cover are loosened
and if the rope groove is worn
worn.
Period : routine
(4) Limit switches
Check whether the securing nuts of the limit switches
are loosened
loosened.
Check whether their position has shifted.
Period: routine
1.5.7 Anti sway system
1.5.7.1 Composition of the sway-
sway-damping device
1.5.7.1 Composition of the sway-
sway-damping device
● The sway - damping device is under the trolley

frame
● Consists of sway
sway--damping wire rope, drum with
clutch , brake
brake, gearbox and motor
● To damp the spreader sway due to the trolley
acceleration and deceleration
● The clutch functions to enable the drum to turn
only in the direction of winding up the wire rope
● So paying out of the rope the drum is engaged
with the transmission shaft
1.5.7.2 Arrangement and Principle
● The motor constantly ensures the winding up of

the slacked sway-
sway-damping wire rope onto the
drum
● When the spreader
p sways,
y the disc brake
connected on the drum shaft provides a certain
force to the tensioned rope to resist the
spreader swaysway.
● The motor winds up the slackened ropes, and
the above-
above-mentioned action is repeated
severall titimes tto continuously
ti l reduce
d th
the sway
● This resistant force may easily be adjusted
through the spring setting
1.5.7.3 Sway-
Sway
y-damping
p g
The brake in this system is released during

hoisting and lowering and is applied when
the main hoisting is stopped and when
trolley and gantry are in operation
1.5.7.3 Sway-
Sway y-damping
p g
(1) during spreader lowering
Under the weightg of the spreader
p each motor is subject
j
to a reverse force, and the inner and outer rings of
the clutch are engaged with each other. The brake is
released
l d andd the
h shaft
h f iis revolving,
l i and
d the
h tension
i
force in the sway-
sway-damping wire rope is the stall force
of the torque motor.
motor In this case sway-sway-damping
device has a little effect.
(2) When spreader is stopped
At the instant when the spreader is stopped and the
brake is applied,
pp , the inner and outer rings
g of the
clutch are engaged from each other and the shaft is
not revolving. If the spreader sways due to any other
reason the brake resists the spreader sway .
1.5.7.3 Sway-
Sway-damping
(3) When the spreader is lifting
The spreader weight is not affected on the wire rope, and
the motors drive the drum to wind up the rope. In this
case, the inner and outer rings of the clutch are
disengaged from each other and the revolving force is
not imposed on the shaft and the brake has no effect
effect.
(4) Trolley in operation (or simultaneous operation of the

trolley and hoisting), gantry in operation.
Duringg the trolley
y runningg ((or simultaneous operation
p of
trolley and hoisting) and gantry traveling, when the
brake is applied the inner and outer rings of clutch are
engaged from each other and the shaft is not revolving
revolving.
In this case if the spreader sways due to some reason,
the motor winds up continuously the slackened wire
rope that reduces the spreader sway.
1.5.7.4 points for attention in operation
After a long period of non - operation or after

disassembly y and re - assemblyy the Crane shall be
first run with no load allowing the reducers,
bearings, etc. to be lubricated fully, then
operation with load can be started.

During
u go oil (g
(grease)
ease) replacement
ep ace e t tthe
eoold
dooil (g
(grease)
ease)
shall be discharged thoroughly. Grease shall not
be mixed because mixed g grease may y result in
bearing damage.
1.5.7.5 Inspection items and period for
maintenance

Check that lubrication is correct
Lubrication shall be done in accordance with the
lubrication schedule.
Period: routine
maintenance
(3) Sheaves
Check
Check whether the sheave bearing is overheated.
It is necessary to inspect the inner part if the
temperature off the
h casing
i iis hi
higher
h than
h the h
ambient temperature by 40°40°C.
Check whether bolts on the hollow cover are
loosened and if the rope groove is worn.
Period: routine
maintenance
Clutch: The model of antisway clutch is

MI750 For detail,
MI750. detail please refer to “Antisway
Antisway
clutch manual”
R d
Reducer: Pl
Please refer
f to antisway
i sway
reducer manual.
Brake: Please refer to “ZPMC YP21LZ-
YP21LZ-
800--560X30 anti-
800 anti-sway brake manual”.
1.5.8 Operator's cab
1.5.8.1 Composition of the Operator’
Operator’s cabin
● Attached to the extended support beam of

the trolley frame with bolts and buffers
● Has window glass in front and rear, and
both sides as well as the front lower part
of the cab
● The operator's seat is located in the front
central part of the cab
● The control console is on the left and right
sides of the seat
1.5.8.2 Inspection Items and Period for
Maintenance
Special the connecting bolts between trolley frame
and cabin
(2) Check the glass of the windows

Keep all windows clean to provide good sight.
Check if there is crack or other abnormal
conditions on the glass especiall
especially floor
windows.
P i d routine.
Period: ti
1.5.9 Power Unit
1.5.9.1 Composition of the Power Unit
● Diesel engine Model 6LTAA8.9

6LTAA8.9--G2 by Cummins
China ,which power is 220BKW
● Alternator MP
MP--220
220--4A by Marathon Shanghai, which
power is 275KVA
● The engine generator set has a common base frame
so that they can be removed by the forklift as a
whole
h l unitit ease ffor maintenance
i t
● The fuel tank is installed outside the sill beam with
capacity of about 1000 L (up to the top level on the
fuel level indicator).
● Provided with protection from overheating of cooling
water, low pressure of lubrication oil, over speed
and frequent starting, etc.
Maintenance
● Make
M k a record d off water
t temperature,
t t oilil pressure,
etc. daily.
● The
Th airi filter,
filt lubrication
l b i ti oilil filt
filter andd ffuell filt
filter
shall be checked and replaced refer to the
manufacturer’s
manufacturer s manual
manual.
● Maintenance of the engine and alternator shall
be done in accordance with ith the Instr
Instructions
ctions for
the diesel engine and the alternator.
1.5.10 Festoon Cable System
1.5.10.1 Composition
p of festoon cable system
y
● Consist of first towing trolley, middle towing trolley, hold

towing trolley
trolley, end towing trolley and towing parts parts..
● Control power of the main hoist, trolley traversing,
spreader
p skewing g and the p power for the spreader
p is
supplied through the festoon cable system
● One end of the festoon cable trolley is fixed to the girder,
andd th
the one cable
bl end d iis fifixed
d tto th
the ttrolley,
ll and
d alsol
the cable is led into the junction box
● Frequently check bolt connections and re - tighten bolts if
they are loosened.
●Check the line bearing g and g guide roller
For details, refer to the Instructions from IGUS

1.5.11 Stairs,, p
platforms and ladders
1.5.11.1 Composition of stairs, platforms and
ladders
Consist of stairs and ladders to EE--house and engine

room, festoon cable system platform, girder
platform platform to cabin
platform, cabin, lithium battery pack
platform, etc..
The platforms and stairs are provided with hot dip
galvanized grating which is anti-
anti-slipping.
Platforms and ladders are painted
painted, and the handrails
handrails,
stairs are hot dip galvanized.
The stairs are connected with platforms through pins.
Maintenance

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

handrail
Period: routine
● Check the p painting

g and g
galvanized surface
Period: routine
1.5.12 Other auxiliary devices
1.5.12.1 Trolley anchor device

1.5.12.1 Trolley anchor device
● At two sides of trolley, there are two sets

of trolley anchor devices
devices.
● Consists of anchor pin, limit switch.
● Iff the trolley is anchored, the trolley can
not move. If the trolley is out of operation,
th ttrolley
the ll shall
h ll b
be anchored
h d properly. l

● Check whether the switch’s
switch s position has
shifted.
Period: routine
1.5.12.2 Trolley travel limit switch
arrangement
1.5.12.2 Gantry tie down
● Consist of magnetic L.S.(for reduce speed), and

mechanical L.S.(for
L S (for over travel stop)
● Before trolley arrived at rated travel range,
the speed of trolley will be reduced; When
trolley arrived at rated travel range, the
trolley will be stopped by PLC control;
The trolley will be stopped by mechanical
over travel L L. S
S. in case of normal stop is
failed.
1.5.12.3 RTG tyre pressure monitoring
system(TPMS)
The RTG TPMS consists of sensor, repeater,

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

manual for RTG TPMS.
CHAPTER 2
Crane Inspection,
Maintenance and Repair
The following works are based on

the safety rules.
2.1 Crane Travel Operation
● In non
non--operational conditions the trolley
shall be anchored
anchored.
● The Crane
C traveling is controlled with
operation switch and limit switch
i t l k th
interlocks; therefore,
f th
the control
t l parts
t
such as limit switches shall not be
removed d without
ith t permission.
i i
2.2 Management
(1) The Crane shall be operated in accordance with operation
Manual for the Electrical System” since the electrical devices are
controlled through
g the PLC and ZPMC Siemens system. y
(2) Before operation the activation of limit switches for every
mechanism shall be confirmed to be accurate.
(3) Pay
P close
l attention
tt ti to t the
th fastening
f t i bolts
b lt off every
mechanism to ensure that they are not loosened.
Particular attention should be paid to the securing bolts
on the main hoist mechanism and on the spreader for
safe load lifting
g and lowering.
g
(4) Pay attention to the brake disc and brake shoe pads
which are easily worn out parts in comparison with
other parts. In addition, clearance between the brake
disc and brake shoe pads shall be kept between 0.5mm
and 1.5
1 5 mm
mm.
2.2 Management
(5) Frequently check that the remaining wraps of the
main hoist wire rope on the drum are more than two.
Check whether the rope clamp bolts on the drum are
loosened and re - tighten them if necessary. Bolt
loosening
oose g may ay result
esu t in tthe
e wiree rope
ope falling.
a g
(6) Malfunction of the limit switches due to wire rope
stretch should be corrected through g adjustment
j of the
rope length. Particularly after rope replacement the new
wire rope may be stretched after a certain time period of
operation
ti and,d th
therefore,
f f the
for th first
fi t stage
t off operation
ti
of new wire rope more frequent inspection should be
made.
made
(7) The wire rope lubrication shall be checked every
day and lubricant added if necessary.
2.2 Management
(8) Replace parts when they are worn to the permitted

limit.
(9) Carefully check the wire rope end securing bolts,
especially the following bolts and re - tighten them:
● Securing bolts on wire rope clamps on the drum;
● During wire rope replacement care must be taken not to

damage the thread on the bolts for the rope clamp
b
because with
ith d
damaged
d th
thread
d th
the b
bolts
lt can nott b
be
tightened to adequate torque. Also take care not to
damage the threads on other bolts of the mechanical
devices.
2.2 Management
(10) After installation has been completed or after re- re-

tightening, loosening of some bolts in mechanical parts
may resultlt iin misalignment,
i li t vibration,
ib ti h
heating,
ti etc.
t ThThatt
may cause reduction of service life of the corresponding
components or may be the cause of running failurefailure.
(11) Routinely re - tighten bolts, nuts, etc.
2.2.1 Table of re-
re-tightening operation of bolts
andd nuts
t
After 7 After 14 After 1 After 3 After 6 After 1
days days month month month year
Motor securing bolts 0 0 0
Brake securing
g bolts 0 0 0
Brake disc nuts 0 0 0
Reducer securing bolts 0 0 0
Shaft securing bolts 0 0 0
frame securing bolts 0 0 0 0
Wire rope clamp bolts 0 0 0 0 0
bolts in control cabinet 0 0 0
bolts in resistor g
grids 0 0 0
bolts in operation box 0 0 0
bolts in limit switches 0 0 0
Items above with marks “0” shall be inspected and re-tightened in
the specified time interval
2.3 Maintenance and Inspection
● Maintenance of the crane is done to ensure good

crane performance
f and
d tto preventt accidents.
id t
● Maintenance includes routine maintenance and

regular
g inspection
p
● In addition,
addition in case of typhoons or earthquakes it
is necessary to inspect and confirm precautions
taken and to inspect after these events
events.
2.3.1 Points for Attention for Maintenance,
Inspection and Repair
(1) Before operation of the Crane the Operation Instructions for

the Crane by the manufacturer shall be thoroughly read and
the operating records shall be checked.
(2) During maintenance
maintenance, inspection or repairing the following
matters must be observed in addition to contacting related
authorities:
If there is a Crane nearby, the anti anti--collision device must be
carefully inspected to prevent collision.
During
D i maintenance,
i t iinspection
ti or repairingi i a sign
i ““under
d
Repair” shall be posted at a conspicuous place under the
Crane
C a e toop protect
o ec pe
personnel
so e from o injury.
ju y
If it is necessary to inspect while the Crane is in operation,
it is strictly prohibited for any personnel to stand or pass
under the spreader.
2.3.2 Record of Maintenance and Inspection
Results
The following maintenance and inspection records
are attached
tt h d tto these
th Instructions.
I t ti
The results are necessary for the Crane repairing

and modification and shall be carefullyy recorded.
2.3.2.1 Routine Inspection Items
Confirming performance and ambient safety

b f
before operation.
ti
Observe the Crane’s condition and stop

operation
p after any
y abnormal condition is found.
After operation has been completed

completed, the Crane
shall be stopped at the correct position and it
should be confirmed that there is no abnormal
condition.
B f
Before starting
t ti operation
ti
Inspection Items Inspection
Method
1.Obstruction within traveling range and the Visual
load traveling path
2. Obstruction on trolley rail track Visual
3. Wire rope jumping off the drum or sheave or Visual
contact of the rope with any obstruction
4. Lack of lubrication in wire rope, strand Visual
breakage, loosening of clamp bolts
5. Inspection
I i off brake
b k pads d Vi
Visual
l
B f
Before starting
t ti operation
ti
Method
6. Remedied condition of the defects found Activation
on previous day
7. Inspection of brakes Starting
8. Various instrument panels and indicator Starting
lamps
9. Activation of various operation joysticks Starting
and button switches
10 A
10. Activation
i i off major j lilimit
i switches
i h ((maini S i
Starting
hoist, trolley, spreader)
D i operation
During ti
Inspection
p Items Inspection
p
Method
1. Abnormal sound, heating, vibration Visual
2. Abnormal current, voltage Visual
3 A
3. Activation
ti ti off th
the spreader
d Vi
Visual
l
Aft Operation
After O ti
Method
1. Inspection of spreader Visual
1.1 Deformation and fracture of base frame Visual
1.2 Deformation and fracture of twistlock pins Visual
and flippers
1.3 Damage and torsion on spreader cable Visual
1.4 Loosening of securing bolts Visual
Aft Operation
After O ti
Method
2. If the various joysticks return to off position Visual
3. If various bearings, gears and other Activation
lubricated parts are normal
4. Any abnormal heating Visual
5. Any fracture or damage on various Visual
components
6. If the power switch is disconnected Starting
Aft Operation
After O ti
Method
7. If power pack is switched off Visual
8. If various components are clean Activation
9. If the operator’s cab door is locked Visual
10. Operation log and record of container Visual
handling for shift transferring
It
Items Inspected
I t d per weekk
Inspection Inspection Items Inspection
Time Method
After 1.Any loosening of bolts and damage Visual
operation of bearings
2. Any loosening of various pins, key Visual
boards and end stopper boards
3.Any torsion, damage, cracks of Visual
cable
bl chain
h i and d any lloosening,
i
corrosion of terminals
4 Activation of electro
4.Activation electro--magnetic Activation
contacts, knife switch, etc.
The objective of this inspection is to find out defects between
monthly inspections
2.3.2.2 Items Inspected every month, every year
The objective of regular inspection is to inspect

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

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

annuall iinspection.
ti
2.3.2.2 Items Inspected
p every
y month,, every
y year
y
Monthlyy Inspection
p Annual Inspection
p
Steel structu
1. Loosening of securing 1. Corrosion of steel

bolts
2. Fracture of welds 2. Peeling off of coating
3 Deformation
3. Deformation, fracture 3.3 Wear of shafts,
shafts pins
ure
of steel
4 Grease for shafts,
4. shafts pins
5. Loosening of bolts on
stairs handrails,
stairs, handrails
platforms
p every
y month,, every
y year
y
Monthlyy Inspection
p Annual Inspection
p
Trolle
1. fracture of welds 1. Rail span

2 Loosening of
2. 2 Elevation difference between
2.
ey rail
fixing bolts the two rails

3. Rail end wear 3. Bending in vertical direction
and sinking
4. Bending
g in horizontal direction
5.Slope
7 Damage and corrosion of end
7.
bumpers
8. Damage and corrosion of rail
p every
y month,, every
y year
y
Monthlyy Inspection
p Annual Inspection
p
gearin
1.Abnormal noise, 1. Cracks of casing

abnormal heating,
ng
abnormal vibration
2. Condition of teeth 2. Loosening of the key
washing
3. Lubrication 3. Deformation of the key slot
4. Oil level, oil 4. Contamination of oil
leakage
5. Loosening of
securing bolts
p every
y month,, every
y year
y
Monthly Inspection Annual Inspection
Bearing
B
1 Abnormal noise,
1. noise 1 Any cutting scrap in the oil
1.
abnormal heating (grease)
gs
2 Damage or
2. 2 Clearance between the pin and
2.
fracture of the body bush
3 Loosening of
3. 3 Wear of the bearing
3.
securing bolts
Sh
1.
1 Wear
Wear, fracture
haft
2. Loosening of the key

3 Deformation of the key way
3.
key
1. Deformation
p every
y month,, every
y year
y
Wheel
W
1 Wear
1. Wear, deformation
of the tread surface
2 Bolts loosening
2.
Drum
1. Loosening of wire 1. Wear on the rope

rope fixing
m
groove
2. Damage to the wire
rope guide
3. Damage to drum
securing bolts
4. Fracture of welds
2.3.2.2 Items Inspected every month, every year
Sheav Monthly Inspection Annual Inspection
1. Revolving condition
2 Fracture
2.
ves
3. Rope groove wear

4. Damage to wire rope anti-
anti-slipping
device
1 Deformation and fracture of the
1. 1 Wear of the pins,
1. pins shafts etc
etc.
Spreader
S
base frame
2. Damage, deformation and wear of 2. Peeling-
Peeling-off of coating
r
twistlock pins, flippers

3. Loosening of securing bolts 3. Corrosion of steel
4 C
4. Center
t tto center
t off twistlocks
t i tl k
5. Activation
p every
y month,, every
y year
y
Grease supplyy
G
1 Contamination of
1.
grease and ageing,
discolor of grease
2. Grease supply at
lubrication points
p
3. Damage and oil
(grease)) leakage
(g g in
piping
p every
y month,, every
y year
y
W rop
Wire
1 Broken wires in
1.
strand
2 Wear and external
2.
pe
damage
3 Bending
3. Bending,
deformation
4.
4 Strand loosening
5. Greased condition
6 Rust and corrosion
6.
7. Fixing condition of
wire rope end
2.3.2.3 Inspection Items after a storm
After a storm or earthquake the Crane shall be inspected.
I
Inspection
ti Items:
It
(1) A
Any obstruction
b t ti within
ithi th
the C
Crane’s
’ ttraveling
li range?
?
(2) Is stowage device in normal condition?
(3) Were the traveling motors and brakes immersed
in water?
(4) Were
W the
th stairs,
t i walkways
lk and
d hand
h d railings
ili
damaged?
(5) Anny deformation or fracture of welds on
structural members?
(6) Did wire ropes jump from grooves of sheaves and
guiding rollers?
(7) Any damage to wire ropes?

(8) Any interruption of oil (grease) supply system?
(9) Any damage,
damage rain water in operator’s
operator s cab,
cab engine
room and electrical room?
(10) Is diesel-
diesel-alternator set normal?
(11) Is insulation resistance value reduced?
(12)Any damage to lighting fixtures
Points for Attention after Inspection:
(1)Add oil (grease) to all oil (grease) supply points

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

run first without load and the action of brakes,
bolts, etc. shall be inspected.
(2)Frequently check the operation joysticks and
keepp them clean. Frequently
q yggrease each slidingg
part.
(3) For motors, electro
electro--magnetic brakes,
resistors, thrusters, operation joysticks etc, refer
to operation Instructions for Electrical Parts.
2.5 Lubrication of the Crane
2.5.1 General
(1) Frequently replenish oil in the gear reducer to

keep p the oil level within specified
p range.
g When the
oil is contaminated, it should be replaced.
(2) At least more than once per month grease all the
l b i ti nipples
lubrication i l until til allll th
the old
ld grease iis pressed
d
out.
(3) Properly grease connection pins pins. For moving
auxiliary devices without grease nipples, drip oil with
oil can.
(4) Brake pads and electrical connectors shall not be
greased (oiled).
2.5.2 Points for Attention for Lubrication
(1) Lubrication materials must be kept clean

clean.
(2) Lubrication greases of different brands shall not
be mixed.
(3) Frequently check sealing of lubrication system.
(4) Select appropriate lubrication materials and
lubricate according to the specified schedule.
((5)Lubrication
) shall be carried out when Crane
power is off.
(6) For revolving parts without grease fittings, the oil
shall be used to drip oil into the clearance for
reducing wear and prevention of rusting.
2.5.2 Points for Attention for Lubrication
((7)) Periodicallyy check quality

q y of oil where
components and parts are lubricated through oil
bath.
(8) For grease lubricated points, the old grease shall
be discharged as much as possible and then the
fresh grease may be added
added.
Note:
The user may carry out frequent maintenance and
inspection in accordance with his effective
practice or the local regulations to ensure the
Crane’s normal operation.
Crane Lubrication Schedule
No Description Lubrication period Lubrication Lubrication

type
yp material
1 All wire Normally 15-
15-30 Follow the Special wire rope
ropes days supplier’s lubrication oil
requirement
i t
2 Main hoist Change oil after Oil bath Refer to main
reducer 400 hrs. of first hoist reducer
running, then manual.
change oil every
5000hrs running
3 Trolley Change oil after Oil bath Refer to trolley
reducer 400 hrs. of first reducer manual.
running, then
change oil every
5000hrs running g
No Description Lubrication period Lubrication Lubrication

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

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

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

After a certain period of operation some troubles
may y appear
pp due to wear and increase of
clearances or fatigue of some major member or
components.
Therefore, the Crane operators must learn to
recognize common troubles and immediately
repair the defective members and components
to ensure the Crane’s safe operation.
2.6.1.1 Trouble in mechanical part
p
Mechanical trouble with the RTG occurs mainly in the
diesel engine alternator set
set, motors
motors, brakes
brakes,
reducers, sheave blocks, drum, spreader,
couplings, traveling wheels, etc.
● Surface wear occurs duringg their movement, and

when the wear reaches a certain value the Crane’s
operation may be affected.
● Brake
Brakes are one of the essential components on the
C
Crane and
d th
their
i performance
f governs th
the
accuracy of each movement and safety of
operation.
operation
p
For the main hoisting, the brakes must be absolutely

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

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

Since the wire rope has a fleet angle to the rope
groove the rope
g p ggroove is seriously y worn at its
tip.
The sheave and drum shall not be used any y longer
g if
cracks are found or the grooves are worn to the
permitted limit. Seriously worn grooves may
make the rope jump out of the groove, and the
broken rim of the sheave may damage the wire
rope or jam
j th
the rope andd fifinally
ll result
lt iin
breakage of the rope.
2.6.1.2 Trouble in the steel structure
The q quality
y of the Crane structure directly
y
affects Crane safety. Once the structure
is damaged
g a serious accident may y
occur.
If cracks appear in the welds, the Crane may
not be operated normally and safe
production may be affected.
2.6.1.3 Trouble in the electrical part
● Motors
Motors are required to have great mechanical
strength
g and highg overload capability.
p y
There should not be any noise due to friction, any
shrill sound or other noise during
g motor running,
g
and they should be stopped for repairs if these
noises appear.
The troubles with the motor mainly are disabling of
starting, high temperature rise and that the power
can not reach rated value during running with load.
2.6.1.3 Trouble in the electrical part
● Electrical equipment
Electrical equipment on a Crane includes motors,
electrical magnet,
g controls, resistors and other
components such as conductors, slip ring
devices and various control circuits.
It is easily affected by shock and vibration, especially
in an ambiance of high temperature, dust, and
high humidity
For details refer to the Electrical Operation Manual.
2.6.2 Causes of Common Troubles and
Troubleshooting
2.6.2.1
2 6 2 1 Causes of general troubles in the Crane
parts and components and their remedies
are shown in the following
g table:
troubles and remedies
Troubles Causes Remedy method
High
g temperature
p in Lack of g
grease or no Add sufficient g
grease
rolling bearing grease
Contamination in the Clean the bearing
b i
bearing with
ith kkerosene and
d fill
with grease
Noise in rolling Poor installation Check correctness of
bearing is increased misalignment of the installation and adjust
bearing or over tightened
and jammed
Damaged or worn Replace bearing
bearing elements
Periodic chatteringg noise Excessive error of the teeth Remedy,
y re-
re-
of the gearing in the pitch. Teeth lateral assemble
reducer, particularly from backlash exceeds standard
the idle gear wheel value
Sharp friction sound and Clearance of gearing is too Remedy, re-
re-
clatter sound in the small, misalignment of the assemble or
reducer
d gear wheel,
h l sharp
h and
d thi
thin replace
l
edge on the teeth top, teeth
face uneven due to wear
Uneven meshing, Defects on tooth lateral Replace
continuous knocking surface (laminated texture)
sound heard from any
point on the reducer
casing and vibration of
the reducer
Knocking g sound Excessive axial backlash Replace
p
in the worm of the worm or the teeth Repair or re
re--assemble
gear reducer, of worm gear are
alternate high seriously worn, pitch
and low and the circle of the gear is
period eccentric in relation to
coincides with the shaft
shaft, accumulated
that of gearing error of the circular pitch
rotation sound of the gear
Heating of the Lack of oil <60°C for
Oil temperature <60°
reducer cylindrical and bevel gear
<70°C for
reducer,, and <70°
worm gear reducer. Oil level
shall be kept between the
two pointer scales
High
g noise of Excessive wear of g
gear Replace
p g
gear wheel
shock in the wheel
gear reducer
Foreign matter in the Remove the foreign matter
casing
i
Bearing is damaged Replace bearing
Bearing Contamination in bearing Disassemble and clean the

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

Brake can not Jammed p pivot linkage
g in Clean up
p the brake element
hold the load lever system jam and grease the pivots
(excessive
Oil (grease) on the brake Clean brake disc and brake
braking
di or b
disc brake
k padsd pads
d with
ith kkerosene
distance of the
trolley or gantry) Excessive wear of the Replace brake pads
brake pads
Main spring damaged or Replace spring or adjust the
loosened results in nut to make the spring
p g
insufficient tension tension sufficient
Loosening of the lock nut Adjust the lever and tighten
of the lever
lever, lever’s
lever s play nut
Burnt spots
p on Uneven clearance between Adjust
j clearance to
brake disc and brake disc and brake pads, make it even, replace
rapid wear of friction appears when released auxiliary spring
brake disc and the disc is heated,
auxiliary spring is damaged or
bent
B k is
Brake i easily
il Adj t
Adjustment t nutt is
i nott tightened
ti ht d Adjust
Adj t brake
b k tighten
ti ht
deviated from or lock nut is not tightened, nut and lock nut, or
the adjusted thread of the nut is damaged replace defective nut
position
Rapid wear or Contamination and lack of Clean and lubricate
frequent grease the wire rope
breakage of
wire rope
Sheave does Lack of lubrication between Disassemble and
not rotate shaft and bush, or bearing lubricate parts and add
grease
Too long too high resistant force at Clean up every pivot
starting time of various pivot points of brake point and grease
brake
Too low oil pressure or oil Clean piping and fill in
piping blocked with oil as necessary
Internal oil leakage Clean pressure relief
value
No ppressure in Orifice of p
pressure relief value Clean p
pressure relief
hydraulic is blocked value
thruster, no
The solenoid is reversely Adjust wiring
braking
connected
t d and
d th
the th
thruster
t
can not be pushed downward
pump fitting is not tightened Tighten the fitting of
the pump
Filter is blocked Clean the filter
Pressure in he plane of the control lever of Find out the failure
hydraulic the adjustable device of point and correct it
thruster can not pressure relief is not leveled;
reach operating control lever has deviated from
pressure value the center of nozzle
Too long
g Insufficient current in the Increase current
braking time solenoid of electro
electro--hydraulic within permitted range
adjustment device
Release time by Small distance between the Slightly tighten the
the hydraulic control lever and the nozzle upper end nut of the
thruster is too cross--spring
cross
l
long, residual
id l Too small diameter of the Enlarge the bore
pressure too nozzle bore diameter
high
The brake can Too high tension of the main Adjust the tension of
not be released spring the spring
Thruster is damaged Repair or replace
hydraulic thruster
2.6.2.2
2 6 2 2 Regular Inspection Items (Mechanical)
for the Crane are shown in the following
table:
Regular Inspection Items
Items method criteria period

&apparatus
1 L b i ti
1.Lubrication Vi
Visual,
l with
ith oilil I di t d range on th
Indicated the scale
l per month
th
oil amount scale
2.Sealing Visual Fixed joint: no leakage. per month
Relatively moving joint: no
drip
3.Running
3 u g Testing,
est g, hear
ea no
o ab
abnormal
o a sou
sound,
d, ab
abnormal
o a per month
pe o t
Reducerr
condition and feel heating

4.Bolt Testing, hear no loosening per month
connection and feel
5.Oil quality chemical to specified by standard every
analysis season
6.Gear meshing Visual
Vis al test tooth face smooth and clean e er
every
normal meshing season
7.Wear of gear Measure wear is less than 10% tooth every year
wheel
h l original
i i l thi
thickness
k

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

grooves
4 F ti
4.Fatigue Vi
Visual
l no damages
d per month
th
cracks
5.Bearing g Visual Proper
p lubrication per month
p
lubrication

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

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

&apparatus
1C k
1.Cracks Vi
Visual
l no cracks
k per month
th
2.Sheave Hearing test maneuverable, no abnormal per month

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

of the groove season
Sheave
4.Wear of Measure 20% original thickness every

groove season
thickness
5.Wear at Measure <50% wire rope diameter every
groove bottom season
diameter
6.Damage Visual no damage per month
7B i
7.Bearing H i
Hearing, visual
i l no abnormal
b l noise
i proper per month
th
lubrication

&apparatus
1B k b
1.Brake base fframe Vi
Visual
l no cracks
k per month
th
2.Wear of thickness of Measure <50% original thickness per month
brake pads
3.Spring Visual, no yield deformation Every
measure season
4.Wear of shaft or Measure <5% original
g diameter per month
p
bore
Brake
5.Hydraulic thruster Visual no oil drip, normal activation per month

6.Clearance when Visual >0 5mm
>0.5mm, per month
released measure <1.5mm
7.Bolts, nuts Knocking test no loosening per month
hammer
h test
8.operation condition Testing and normal operation, reliable, per month
observe no abnormal heating, smell,
and action

&apparatus
Brake d
1.Brake disc Visual no cracks per month

body
disc
2 Wear in disc
2.Wear Measure <4% original thickness every
thickness season
3.unevenness Measure <1.5mm
1.5mm every
of disc surface season
4.Friction Visual no cracks per month
surface
f
Coup
1.Coupling Visual no cracks per month

body
pling
2.Pins Visual no damage, normal wear per month


&apparatus
Wire rop
1.Wire rope end, Visual no abnormal condition, per month

screw lever no cracks
2 Bolt
2.Bolt Visual
Visual, Normal no loosening
Normal, per month
pe suspend
connection knocking test

3.Wire rope Visual Normal operation, no per month
support rollers deformation at deport,
no cracks
Lubricatio
1 Grease
1.Grease Visual To meet requirement per month
amount
2.Quality of chemical To meet regulation per month
on
grease (oil) analysis

3.Nipples and Visual No damage, unblocked every
tubing season

&apparatus
Trolle
1.Wheel body Visual no cracks per month

ey whe
2.Wear of Measure <50%

50% original thickness every
wheel flange season
thickness
eels
3 B di
3.Bending M
Measure <20%
20% original
i i l thi
thickness
k every
deformation of season
wheel flange in
thickness
4.Wear of tread Measure <15% original thickness every
in thickness season
5.Ellipticity Measure <1mm every
season

&apparatus
Rubber tyres
1.Inflation Measure 9.9 kg/cm2 per week

pressure
2 Surface of
2.Surface Visual no cracks per week
the tyres
3.Wheel Visual, Proper lubrication, no per week
bearing hearing abnormal
4.Connection Visual, Normal condition, no per week
b lt
bolts k
knocking
ki ttestt loosening
l i

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

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

cover
4.Diesel fuel Visual no missing, no damage per week
tank cover
5.Fan belt Test Tension meets requirement per month
6.Sealing
g Visual No leakage
g per week
p
7.Abnormal Hearing No abnormal noise per week
noise
&apparatus
1.Carbon brushes & Test run, visual No sparks
p during
g running
g per week
p
commutator
2.Wear of carbon Measure Thickness >20mm per season
brushes
3.Pressure of brush Measure 1.8
1.8--2.0N/cm2 per season
spring
>1MΩ in cold state
Alternator sset
A
4 Resistance of
4.Resistance Measure >1MΩ per season
insulation Ω in hot state
>0.5MΩ
>0.5M
5.Wire connection Visual, knocking No damage, no loosening per week
t t
test
6,Filtered cover of the Visual No dust & foreign matter per week
ventilator
7.Transmission bolt Testing No defects, tension meets per season

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

&apparatus
Trolley horizont
1.Horizontal Visual No defects such as per month

wheel cracks
body
h
2.Clearance Measure 2--3mm

--3mm per month
between the
tal whee
guiding
idi railil
3.Bolt Visual, No abnormal condition, per month
connection knocking test no loosening
el
4.Lubrication Lubricate Proper lubrication per month
5 Wear
5.Wear Measure Meet technical per
requirement season
&apparatus
Gearing
1 Gear
1.Gear Visual no cracks,
cracks no teeth per month
wheels breakage
2.Pitting on Visual <30% meshing face, per month
teeth face depth >10% original tooth
thickness
3 Wear of
3.Wear Measure GB6067--85
GB6067 per year
tooth
thickness
4.Lubrication Visual Proper lubrication per month
Universal s
1.Connection Visual, No loosening correct per week

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

shaft

&apparatus
sprocke
1.Running Visual No abnormal condition per week

Condition inspection
et and ch
2.Damage Visual No damage per week

hain
3.Lubrication Visual Proper lubrication per week

Bumper
B
1B
1.Bumper Visual
Vi l N d
No damage & cracks
k per month
th
body
2.Support
pp Visual No cracks,, firm per month
p
knocking connection
3.Spring Visual No abnormal condition per month

&apparatus
twist blo
Headblo
1.Cracks, Visual, NDT No cracks, no damage per year

damage
ock
ock
2.Wear
2W I
Inspection
ti A technically
As t h i ll required
i d per
season
te
Spreaderr
1 Load
1.Load Visual
Visual, No damage per month
elescopic
bearing Measure
2.Rail Visual, No defects, wear within per month
Measure permitted range

&apparatus
Cable c
1.Cable Visual, perfect no loosening per month

clamp knocking
chain
2 Roller
2.Roller Visual proper lubrication,
lubrication no per month
damage
3.Support Visual perfect per month
bracket
4.Bolt Visual, No loosening per month
connection
ti k
knocking
ki
5.Cable Visual no damage per month

&apparatus
1.Plastic Visual No plastic deformation per month
deformation
Sp
preader twist
2D
2.Damage Visual
Vi l no damage
d per month
th
3 Turning
3.Turning Testing 0 90
0, per month
t
angle
loc
4.Wear Measure As technically required per year

ck
5.Cracks Visual NDT No cracks per year


&apparatus
S
Steel
Box section Painting: No large area of peeling off per season

teel stru
members Visual,
telescope
ucture
Welds: No cracks, ultrasonic and X-

X-
Visual, ray test if necessary depth
telescope rulers of corrosion <10% weld
height
Plate surface: No cracks, local deformation
Visual,
Visual rulers <3%depth of corrosion<10%
Walkways & Oil (grease) Normal walking, No damage per month
stairs contaminated,
d
damage: Vi
Visuall
Railings Damage: Visual No damage per month
The End
Thank you!

Training For KOJA RTG

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Training For KOJA RTG

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Training

General features of RTG Cranes

● Powered with a diesel-

● Equipped with a telescopic spreader which is able

● Spreader slewing device for easier spotting of the

pass across 6 rows of containers p

Gantryy frame: box-

Trolleyy rail: clipped

Over load protection device

Over speed protection

● One set of trolley driving device on the

Lighting and signaling for operation at night

As shown in Figure 1.2-

11-Main hoist mechanism

Description Value Unit Remarks

Lifting height Under spreader 18.2 m

empty spreader 55 m/min

Gantry travel speed empty spreader 90 m/min

Number of wheels/No. of driving wheels 8/4 pieces

● Welded steel structures always

● The cracks grow when subjected to fluctuating

● Periodic inspection is required to detect fatigue to

● MT shall be used at the critical locations of fillet

●Magnetic Particle Testing

(1) All bolted and welded joints shall be visually

(2) Visual inspection shall be performed by a certified

(3) NDT inspection shall be done by qualified person.

(4) NDT shall comply with the requirements of all of

(5) Required inspection is shown on the attached

(6) Where MT or UT inspection is indicated on one side

(7) Inspection of bolts shall comply with AISC

All indications of defects should be shown on the

((1)) Crane identification.

((2)) The side and extent of defect .

((3)) Weather defect is in the toe of the weld,

((4)) Defect location: right-hand

((5)) Method of testing:

((1)) Initial inspection:

(2) Complete inspection: Visual and NDT as shown in

((3)) Maintenance inspection

(1) Work shall be conform to the requirements for

(4) Welders and welding operators shall have current

1.5.1 Gantry traveling mechanism

● Eight rubber inflated tyres

After a long term of non-operation

The crane shall first be run without load allowing

Check whether lubrication is correct. Lubricate in

Period: routine and once per month

Check whether oil level is adequate.

Check that everyy tyre

((6)) Slew bearing:

(6) Slew bearing:

For detail,, please

((7)) Electric screw p

The following works are based on the safety rules.

● Gantrytyre replacement shall be carried out in

● Consider the following basic steps to accomplish

(1) Before replacement, preparation work shall be done

(2) The working area shall be clear and enclosed with

(3) The crane is at non working condition, the trolley shall

(4) Jacking up the gantry leg by two 20 t jacks which shall

(5)Dismantle the bolts connecting between the rim and