RTG Mechanical Maintenance Manual

4 Crane maintenance instructions

4.1 Summary

The service life of crane and auxiliary components greatly depends on the purchaser’s proper use, safe
operation and timely maintenance.

This Chapter gives a system expatiation on how to maintain the Crane components correctly and timely.
Crane maintenance mainly includes the following five parts: cleanliness, fastening, adjustment, lubrication
and inspection. The timely maintenance on the Crane has an important meaning of reaching or exceeding
its potential service life.

4.2 General

Crane Maintenance work covers routine maintenance and inspection. This Chapter focus on the primary
requirement about the Crane routine maintenance and inspection.

Check whether the crane is in a safe and technical state. The main work of the inspection and routine
maintenance includes cleanliness and lubrication, besides also focus on the adjustment of fastening and
routine spot-check and periodic inspection.

The basic methods are visual inspection and functional tests. If these methods are not available,
disassemble the Crane parts to check the inside of these parts. The Chapter 5 “Replacement of wearing
parts” describes the process of the parts of Crane disassembly and change for new.

This chapter mainly describes the follow aspects:

1. The cleanliness of the Crane

2. Inspection and fastening of fasteners and fittings
3. Adjustment about the concentricity
4. The lubrication
5. Inspection and preventive actions

In addition to this maintenance manual, all subcontractors have manuals for their own components. To
maintain such components, please refer to their manuals. The list of these manuals is in Table 4- 1 as
follows.

Table 4- 1. Manual from Subcontractors（Mechanical Part）

Reducer ZPMC

Gantry Cable reel WAMPFLER

Engine Volvo

Generator Stamford

Brake ZPMC

Drum coupling ZPMC

© ZPMC 2016. All rights reserved. Revision: A

1
 RTG Mechanical Maintenance Manual

Motor coupling ZPMC

Head block ZPMC

Spreader Stinis

Power Chain IGUS

system

Gear motor for Nord

auxiliary

Electric push rod JIUNENG

for gantry

Wire rope Bridon

Tire ZPMC

4.3 Cleanliness

The dust, oil dirt, water, impurity which interfusing into the lubricant, rust and the other dirt may cause the
Carne parts corrosion. They can speed up the abrasion of the parts, reduce their original functions and
even destroy them. Such as reduce the braking torque, bring the electrical system short circuit or other
malfunction, affect the air tightness of the hydraulic system and even destroy the hydraulic parts to bring
serious system malfunction etc. Therefore, the purpose of cleaning is not only to maintain a good working
environment, but to maintain the Carne with good performance and extend its service life. During the
routine maintenance work, any pollution that can adverse effects on Carne parts must be removed in time
and keep the Crane clean without dust and oil dirt. Below are some common methods and examples the
cleanness.

4.3.1 Major methods of cleanliness

4.3.1.1 Dry cleaning

“Dry cleaning” adopts physical methods to remove the contamination from the surface without water or
solvent. See Figure 22. The main methods including:

1. Use vacuum cleaner that to remove the dust and small garbage from the surface of the body directly.
To create a clean environment and improve the service life and stability of Crane, the place where
mechanical and electric parts concentrated like machinery house, electric house and cab must be
cleaned regularly.
2. Use Air compressor and air blower to remove the powder, iron chipping which falling off easily from the
surface of the Crane body directly. It applies in cleaning the faying face of the precision bearing and
bearing hole and wiping off dust from the surface of complicated shape parts, electric components and
other components.

3. Cleaning by machining:

a. Use wire brush or electric polisher with copper brush. This method can remove the flotation rust
or metal surface treatment before repairing paint.
b. Cleanness by finish machining such as turning or grinding. This method only adopted in
renovating the defective surface such as bulge or sunken in the brake disc, brake lining and so

© ZPMC 2016. All rights reserved. Revision: A

2
 RTG Mechanical Maintenance Manual

on.

Figure 22. Routine dry cleaning method

1. Industry Cleaner 4. Wire Brush

2. Air Compressor 5. Copper Brush
3. Air blower 6. Corner Grinder

CAUTION

Necessary protective equipment such as the goggles, gauntlet and costume worn to
prohibit hurting the body by powder, scrap iron and even the cold wind.

Some cleansers such as methylbenzene, dimethyl benzene, acetone, and

trichloroethylene are poisonous. Read the related instruction book carefully before
using it.

4.3.1.2 Using cleanser

The cleanser applies in when the oil dirt on the metal surface is difficult to remove. For chose the cleansers,
pay attention to the problem that the solvent or cleanser based on halogenated hydrocarbon like
trichloroethylene and dichloromethane can bring chemical reaction (inject little water into the
trichloroethylene can generate the hydrochloric acid) on the aluminum parts, austenitic steel and
galvanized parts which can lead to the metal parts oxygenized. In extreme circumstances, such reaction
can lead to explosion. So must avoid using the solvent or cleansers based on halogenated hydrocarbon to
clean the metal Crane parts. In addition, must not use the acid and alkali liquor (elements or stripping
agents) to clean the Crane metal parts also, because they can damage the parts directly. For the common
dirt, use the general gasoline or industrial benzene cleanser that is easy to buy in the supermarket. For the
dogged dirt, use the dimethyl benzene cleanser.

4.3.2 Main cleaning work

The following are some typical examples of cleanliness

© ZPMC 2016. All rights reserved. Revision: A

3
 RTG Mechanical Maintenance Manual

4.3.2.1 Cleanliness of common parts

1. Every rotating pin shaft of brake should be clean and free in rotation. No paint contamination and rust.
2. Keep the cooling fan filter of the motor clean, replaced regularly and well ventilation
3. Keep the internal of gear reducer clean. Keep the bottom of the housing clean when change the oil.
4. Keep the surface and both sides of the running rail of the trolley clean and no foreign matters.
5. Keep the surface and both sides of the gantry runway clean and no foreign matters.
6. The gantry part is easy to get dirt and must to clean them periodically.
7. Keep the glass in the operator’s cabin clean to supply a good view to the operators.
8. Clean the Indication lights if there is any powder dust or other contamination so that the operators and
maintenance persons can identify the color of the lights clearly.
9. Keep all rear mirrors in the operator’s cabin clean.
10. Remove excess grease and oil from the lubrication process of the Crane components. The clean
period includes both the process of lubricating and a short time of operation after lubricating.
11. Clean the dirt parts before reassembling.

4.3.2.2 Cleanliness of the electric elements and system

1. Keep the E-room clean. Close the doors and windows. Use the vacuum cleaner to clean the powder
dust inside of the control panel and other places. Keep the pressure fan in the operation state all time.
2. Use dust collector to clean the places where easy to sorb dust. For examples: The CMS control panels
in E-room and the computer screens and so on. (See Figure 23).

Figure 23. PLC controlling panel

4.3.2.3 Cleanliness of the hydraulic system

Clean oil is the key part of the hydraulic system. There are many precision components in the hydraulic
system. Some of them has the damper pores and some of them has the gaps. If the impurity gets into the

© ZPMC 2016. All rights reserved. Revision: A

4
 RTG Mechanical Maintenance Manual

small damping pores or the gaps, they can cause the precision components damaged during running and
the oil channels jammed and can endanger the safety running of the hydraulic system. Generally, the
impurity contamination ways including: the hydraulic oil is not clean, the oil-filling tool is not clean, the oil-
filling process and repair and maintenance process are not right, the slug from the hydraulic elements is
slipped and avoid the air and water enter into the hydraulic system.

 The ways to prohibit the impurity gets into the hydraulic system:
1. Keep the hydraulic oil filtered and the oil-filling tool clean before filling the oil. Avoid removing the filter
placed at the entry of the oil tank to speed up filling. The oiler must use clean gloves and clothes in
case the solid-impurity or fiber-impurity gets into the oil.
2. During the maintenance, disassemble the oil-filling cover, the filter cover, the inspecting holes and the
oil pipes. Keep the oil-channel system away from the flying dust. Thoroughly clean the disassembled
parts before opening them. For example, when disassemble the cover of the oil tank , remove the dirt
around the cover and then open the cover to clean the dirt left in the connection (do not use water to
clean the dirt in case the water gets into the oil tank).
3. Choose the cleaning materials without fibre impurity dropping off and hammer with rubber beating
surface if they have to be used. Hydraulic elements and hoses should be cleaned and blow dry before
assembling. The filter also should be cleaned when oil changes. Chose the same type of cleaning oil
with the hydraulic system. The oil temperature ranges at 45～80℃ and not lower than 25℃. Keep the
cleaning oil in a large flow to remove the impurities from the system as far as possible. Clean the
hydraulic system more than three times and after each cleaning, let the cleaning oil flow out before it
cool down. After the cleanliness, fill the new oil after clean the filter and change the filter cartridge.
 Keep the air out of the hydraulic system

If the air gets into the hydraulic system, it can cause cavitation erosion on the hydraulic elements and
increase the compressibility of the oil to leave the operation with instability, reduce the work efficiency and
cause the actuator act as “crawl”. In addition, the air can also oxidize the oil and speed up its
metamorphism. To keep the air out of the hydraulic system, pay attention to the following list:

1. Random check after maintenance and changing oil. Remove air from the system before working.
2. The mouth of the inlet pipe in the pump cannot come out of the oil lever and keep the inlet pipe is
sealed well.
3. Keep the driving axis of the lubropump in a well obturation condition. Use the authentic oil seal
recommended by the supplier to ensure the function of airproof and oil proofing.
 Prevent water penetration into hydraulic system

If the oil contains excessive water, it can leads the hydraulic elements corroded, the oil emulsified and
metamorphosed, the tenacity of lubricating film reduced and mechanical abrasion speedup. If the water in
the oil exceeds standard, the hydraulic system must be cleaned thoroughly and replace the oil.

 Inspection of the filter element

Filter is the cleaning tool of the hydraulic system. Inspect the degree of the dirt of the filter and the
characters of the impurities on the filter element to provide evidence for further fault diagnosis.

© ZPMC 2016. All rights reserved. Revision: A

5
 RTG Mechanical Maintenance Manual

4.4 Fastening

4.4.1 Grade of fasteners

Most of bolts used on the crane are according to the Chinese standard of GB and it is equivalent with the
ISO standard. The bolts are also equivalent with the American metric bolts in specification and have
parallelism relation in grades, so it is easy to find suitable bolts for replacement. Table 4- 2 is another
comparison table for bolt grades in different standard.

In addition, it is very common to see the strength grade marked on the head or end of the bolt (See Figure
24). The strength grade of bolts used in the Crane is usually greater than or equal to 8.8 for the normal
carbon steel and alloy steel bolts. So, do not use the bolts or nuts with the strength grade lower than 8.8
during the repair replacing process.

The strength grade classification as mentioned above is suited for the bolts with the material carbon or
alloy steel. They are not suitable for the stainless steel bolts. For detailed information, refer to other related
data. Generally, for the stainless steel bolts with size smaller than M14 in Crane, use stainless steel nuts or
gaskets, the grade of the bolts is usually A2-70 or ASTM316. Use the bolts or nuts during the repair
replacing process.

Table 4- 2. SAE Grade and ISO Grade

ISO898­1 SAE J429 ISO898­2 SAE J995

Bolt Bolt Nut Nut

Grade 4.8 Grade 1 4

Grade 5.8 Grade 2 5 Grade 2

Grade 6.8 6

Grade 8.8 Grade 5 8 Grade 5

Grade 9.8 9

Grade 10.9 Grade 8 10 Grade 8

In addition, there are fasteners specially used for metal structures. There are two main grades: the high-
strength bolts with ISO Grade 8.8 and 10.9 (equal to ASTM A325 and ASTM A490). Usually, the bolt head
and nut size are bigger than normal ones and they supplied as a complete set including the bolt, nut and
two washers (See Figure 24, a set of bolt connection with grade 10.9). There are strict requirements on
those high-strength bolts for application and here is only some primary knowledge in this chapter. For more
detail information, refer to the relevant standards. For the bolts of ASTM A325 and ASTM A490, refer to
“Specification for structural joints using ASTM A325 or A490 bolts” written by AISC. Most of the tightening
of bolts has torque requirement and need the torque wrench to finish the tighten process. See Figure 25
with some typical torque wrenches.

© ZPMC 2016. All rights reserved. Revision: A

6
 RTG Mechanical Maintenance Manual

Figure 24. 10.9 Grade fastener for structure

Figure 25. Typical torque wrench

1. Hand torque wrench 3. Electric torque wrench

2. Hydraulic torque wrench

4.4.2 Inspection of bolts

The bolts can be loose due to alternating loading during working. Usually it is necessary to pre-tight the bolt
in a certain degree to reduce the stress amplitude.

Periodic inspection aims to insure all bolts under uniform force and to replace the bolts with yield and
lengthened or with suspected a faulty.

The inspection process must be processed during the Crane is powered off. There are two main methods
to check the bolts including visual check and using wrest wrench. Visual check is common used.

© ZPMC 2016. All rights reserved. Revision: A

7
 RTG Mechanical Maintenance Manual

4.4.2.1 Visual check

Using the following methods for visual check, refer to the Figure 26.

Figure 26. Methods of Finding a Loosened Bolt

1. Use taper drift to knock on the head of the bolt to reflect the looseness/tightness of bolts by hearing the
sound.
2. Check to see if the nut and the connecting part are in position (some key bolts and connecting parts
position can be marked out with a marking pen during the manufacturing of ZPMC equipment). If there
is a deviation in the mark position that means the bolt is loose.
3. Visual check the paint film around the nuts and connecting parts is also a method to know whether the
bolts are loose. If the paint film around the bolts with a crack, it means there is necessary to check the
tightness of the bolts.

4.4.2.2 Use the torque spanner

 For common fasteners( excluding the fasteners used on metal structures）

1. The Crane must be powered-off before inspection and make the bolts idly without working stress.
2. Remove the dirt and paint on the surface of fasteners. Spray a thin layer of oil-lubricant rust remover
(CRC or other equivalent products) on the nuts and washers. The lubricant rust remover can work after
10~20 minutes.
3. Mark the original location of the nut by a marking pen on the joint surface between nut and washer

© ZPMC 2016. All rights reserved. Revision: A

8
 RTG Mechanical Maintenance Manual

(see Figure 27)

Figure 27. Marked bolt

4. Use the marked torque wrench to give a 75% (compared to the final torque, the same below) torque to
the each bolt nut.
5. Check whether the nut turns. If it turns, mark it out by a marking pen or paint so that to fasten or
change later.
6. Replace the bolt if needed.
7. Repeat the process 3-6 to inspect the other bolt joints.
8. The nut with turn problem checked out before must release the bolt and refasten according to the
methods mentioned in the section 4.4.3.3.
9. The nut with no turn problem must refasten according to the follow 10-11 steps.
10. Turn the nut about 30° by a torque spanner to loosen the nut.
11. Refasten the nut to its pre-tightening torque requirement.
12. Remove all dirt and use proper solvent to clean bolts, nuts, washer and places around the joint surface
of the structure, and repair the damaged paint according to paint repairing process.
 For high-strength fasteners used on the steel structure (take the flange connection as an example)
1. The Crane must be powered-off before inspection and make the bolts idly without working stress
(without loading).
2. Remove all dirt and paint on the fasteners if there is with loading. Spray a thin layer of oil-lubricant rust
remover (CRC or other equivalent products) on the nuts and washers. The lubricant rust remover can
work after 10~20 minutes.
3. Mark the original location of the nut by a marking pen on the joint surface between nut and washer
(see Figure 27).
4. Use the marked torque wrench to give a 75% (compared to the final torque) torque to the each bolt nut.
5. Check whether the nut turns. If it turns, mark it out by a marking pen or paint so that to fasten or
change later.
6. Repeat the process 3-5 to inspect the other bolt joints.
7. Account all the nuts that marked rotation and need to replace.
8. If the account of the bolts marked need to replace exceeds 20%, use the same grade bolts to replace
them.

© ZPMC 2016. All rights reserved. Revision: A

9
 RTG Mechanical Maintenance Manual

9. If the account of the bolts marked need to replace under 20%, replace all the marked bolts together
with the bolts on their both sides.
10. The non-rotating nuts must refasten according to 11-13 steps.
11. Turn the nut about 30°by a torque spanner to loosen the nut.
12. Refasten the nut to its pre-tightening torque requirement.
13. Remove all dirt and use proper solvent to clean bolts, nuts, washer and places around the joint surface
of the structure, and repair the damaged paint according to paint repairing process.

4.4.2.3 Inspection period for the fasteners

Table 4- 3. Inspection Period for the Fasteners

INSPECTION INSPECTION PERIOD BEFORE THE INSPECTION PERIOD AFTER THE

TYPE FIRST MAINTENANCE * FIRST MAINTENANCE *

Visually check Per 3 months（except special positions） Per 6 months（except special positions）

Use torque 10% spot-checked (the sixth month or 50000 the 5th, 15th、25th、30th year
spanner work cycle)

Replace If needed If needed

fasteners

NOTE: The first maintenance here gives priority to the first expiration of the 6th month
or 50000 in work cycle.

Because the bolts are easy to loose in the primary stage, apart from the requirement from Table 4- 3, it is
necessary to full-around inspect the tightness of bolts after the Crane put into operation for six months or
50000 work cycles (which comes earlier). High-strength bolts and the bolts with other torque requirement
must spot-check by 10% for each group. If any bolt found loose, all bolts within this group must thoroughly
check. In addition, the bolts bearing vibrating or varying load and have no effective anti-loosening methods,
the inspection period should be short to avoid accidents. Especially the electrical wiring and connecting
bolts and small electrical parts and connecting bolts, such as bar wiring connection in control panels, motor
wiring, junction box wiring, various kinds of limit switches, encoders and cam limit switches (inside and
outside), usually have smaller area and size. Impact and vibration during the operation of the Crane can
cause the bolts loosen. Once the bolts are loose, the electrical control fails. Therefore, must carry out the
inspection of fastening condition for this kind of bolts and inspect the wiring condition periodically.

4.4.3 Process for bolt’s replacement and tightening

4.4.3.1 Replacement standard

Replace the bolts under the following condition:

1. The bolts need replace mentioned in the above section.

2. The bolts with such defects like impairment, distortion, slide tooth, lacking tooth, corrosion, big change
of the screw roughness and so on.

© ZPMC 2016. All rights reserved. Revision: A

10
 RTG Mechanical Maintenance Manual

3. If the bolts following the standard GB1228, GB1229, GB1230 ASTM325 and ASTM490 are hot dipped
galvanizing, they are not allowed to be used repeatedly, and must be replaced once loosen after being
final tightened. According to the standard AISC, only the bolts with black finished allowed to use again
with engineer’s permission. In addition, when tighten the bolts cause their adjacent bolts loosen, the
adjacent bolts are no need to replace.

4.4.3.2 Tightening torque for the bolts

Table 4- 4 lists out the tightening torque for the small size stainless steel (grade A2-70) bolts. This torque is
smaller than normal bolts torque. Table 4- 5 lists out the tightening torque for common bolts, screws, studs.
If there is no special requirement on the relevant drawings or service manuals, it is available to use the
data directly in the table. Pre-tightening torque Mo＝K*Fo*d (K is the torque factor, Fo is the pre-tightening
force and d is the bolt diameter). The friction factor between the nut and washer, the nut and bolt changes
can cause the torque factor K change correspondingly. So even the required pre-tightening force is
unchanged, the torque can be not a constant but change. Generally under dry connection, the torque factor
K＝0.145, if a little lubricant or MoS2 is filled, K=0.12. For the important connection, the torque factor is got
by spot-check of the each bolt or that of the same connection and measuring through experiments. It is
necessary to measure the real torque factor of all the high-strength bolts or other similar connection used
on the ZPMC before final tighten.

Table 4- 4. Tightening Torque of Stainless Steel Bolts with Small Size (Grade A2-70)

Size M5 M6 M8 M10 M12 M14

Tightening torque 3.2 5.5 13 26 46 74

(Nm)

Table 4- 5. Tightening Torque of Major Bolts

SIZE TIGHTENING TORQUE (NM) TIGHTENING FORCE (N)

8.8S* GRADE 10.9S * 10.9S** 8.8S

8.8S**

M 12 66 54 92 76 37766 53109

M 14 105 87 147 122 51520 72450

M 16 163 135 229 190 70336 98910

M 18 225 186 316 261 86016 120960

M 20 318 263 448 370 109760 154350

M 22 433 358 609 504 135744 190890

M 24 550 455 774 640 158144 222390

M 27 805 666 1132 937 205632 289170

M 30 1093 905 1537 1272 251328 353430

© ZPMC 2016. All rights reserved. Revision: A

11
 RTG Mechanical Maintenance Manual

SIZE TIGHTENING TORQUE (NM) TIGHTENING FORCE (N)

8.8S* GRADE 10.9S * 10.9S** 8.8S

8.8S**

M 33 1488 1231 2092 1731 310912 437220

M 36 1911 1581 2687 2224 366016 514710

M 39 2473 2046 3477 2878 437248 614880

M 42 2851 2360 4009 3318 468168 658362

M 45 3818 3160 5369 4443 585109 822809

M 48 4593 3801 6459 5346 659973 928087

M 52 5937 4913 8349 6909 787401 1107282

NOTE: * = without lubrication; ** = with a little lubricant or MoS2 lubrication

NOTE: The torque listed in the table is only suit for the connection surface without
tighten torque requirements. The bolts in such connection are only bearing pre-
tightening force, and the working force is vertical to the bolts and transferred through
the friction from the connection surface. For those bolts bearing not only the pre-
tightening force but also the working force, for example the bolts used in the bearing
pedestal and the motor base, the pre-tightening force must be recalculated and the
tightening torque is often less than the one listed in the table in such situation and
must refer to the relevant drawings.

4.4.3.3 Bolt fastening and replacing process

 Fastening process of the general blots (excluding the high-strength bolts for steel structure) during the
first installation or replacement.

1. Check the washer whether flat or not, and clean without oil dirt and burr.

2. Clean the connecting surface of the structure and washer and ensure the surface smooth.
3. Clean the bolts and nuts.
4. Set well the washer and ensure the inclined plane touch the bolt head or the nut.
5. Do an initial tension of 75% of the final tension .To ensure the flange bolts load equally, fasten the blots
in the order from the rigid joint to free end or from the center of the bolt group to around. If the
connection steel plate warps and the connecting bolts are fastened from the two ends to the middle,
the middle of splice plate may plumps up and cannot keep closely which lead friction force lose partly.
For detailed fastening order can reference in Figure 28. Make marks on the large hexagon head bolts
with high-strength during the first fastening to avoid missing.
6. Finally fasten the blots to 100% required torque. The fastening order of flange connecting bolts is

© ZPMC 2016. All rights reserved. Revision: A

12
 RTG Mechanical Maintenance Manual

similar to the first fastening. Generally use two kinds of color to distinguish the first and final fastening.

 Replacement of the high strength bolts for steel structure. (flange connection）

1. To ensure the same torque factor, the high-strength bolts replaced in one time should be the same
batch.
2. Ensure the fasteners with enough quantity, have the correct fastener grade and tightening torque.
Revise the torque wrench repetitiously before using.
3. Check the washer whether flat or not, and clean without oil dirt and burr.
4. Clean the joint surface of the structure and washer and ensure the surface smooth.
5. Clean the bolts and nuts.
6. Use a new bolt to replace the old one marked for replacing and tight an initial tension of 75% of the
final tension immediately. Pay attention that there is only one bolt in the state of the loose and can be
disconnected at any time. Ensure replace and fasten the blots one by one.
7. Destroy the old bolts immediately to prevent them from using again.

Tighten the new bolts finally after changing all old bolts. The tighten sequence refer to Figure 28.

Figure 28. Fastening order of the flange bolts

4.4.4 Anti­loosing methods for bolts

It is very important to adopt some methods to prevent bolts loosen. The loosen bolts can reduce
the structure strength. Besides, the downfallen bolts pose a direct threat to people's safety.
The common methods of anti-loosening used in Crane shows in

Table 4- 6.

Table 4- 6. Anti-loosening methods of the bolts used on the container crane

METHODS INSTRUCTION /APPLICATION FIGURE FOR EXAMPLE

© ZPMC 2016. All rights reserved. Revision: A

13
 RTG Mechanical Maintenance Manual

METHODS INSTRUCTION /APPLICATION FIGURE FOR EXAMPLE

using anti­ The anti-loosing glue is often used in

loosing the fields with limited place, for
glue example used on the fixing bolts of
the anti-abrasion block for the wire
rope.

Lock Both of these methods are

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

Nylon anti­ Nylon anti-loosing nut is the most

loosing nut widely used and it is reliable to anti-
SPL nut loose when matching with bolts.
Double nuts PL nut has a strict requirement on
the retightening torque and the nuts
can be reused.
Double nuts are not used commonly
on the crane for inconvenience.

Spring Spring washer is not very reliable

washer or and usually generates yellow water
other anti­ when used outdoors. Usually they
loosing
are not used in ZPMC’S crane. But
washer
in some outsourcing or unimportant
parts the stainless steel washers are
still used.

4.4.5 Pin connection

Lubricate the pins well every time before installation. After the installation, re-lubricate all accessible spots
of the pins. In addition, if use snap ring to fixing the pins, the snap ring only can be used once. Use the new
snap ring after dismounting the pins.

4.5 Inspection of alignment

You should take periodic inspection for rotary components like couplings, because the alignment of
couplings has great influence on the mechanism running and life. In the first year of service, the inspection
cycle should be shorter, e.g., once per three months. After the mechanism gets stable in the service, the
inspection cycle can be lengthened suitably. This inspection is mainly for the motor coupling and drum
coupling of main hoist, and trolley travel drive and the motor coupling of gantry travel drive. The standard of
alignment is determined by the request of motor’s alignment and the style of coupling. Figure 29 shows the
main check items of coupling’s alignment. Table 4- 7 shows the standard’s detail of coupling’s alignment.

© ZPMC 2016. All rights reserved. Revision: A

14
 RTG Mechanical Maintenance Manual

Figure 29. The check items of coupling’s alignment

Table 4- 7. The check items of coupling’s alignment

PART STYLE OF ΔR MM ΔB ΔA MM
COUPLING

Main hoist high­ flexible coupling ≤0.08 0.18 mm ＝Δr

speed coupling

Trolley high­speed flexible coupling ≤0.08 0.18 mm ＝Δr

coupling

Gantry high­speed flexible coupling ≤0.08 0.10 mm ＝Δr

coupling

Main hoist drum Gear coupling --- 10’ ---

coupling

4.5.1 Redress methods for alignment of motor and gear reducer

4.5.1.1 Use the laser alignment measuring instrument controlled by microcomputer

See the following diagram and procedures:

1. Don’t take apart the coupling in the inspection. The laser generatrix is fixed on the shaft on one side of
the coupling and the receiver is fixed on the other side. (See Figure 30). Both the generatrix and the
receiver should round together.

© ZPMC 2016. All rights reserved. Revision: A

15
 RTG Mechanical Maintenance Manual

Figure 30. Alignment Check by Laser Measuring Instrument

2. Input related dimensions into the microcomputer, such as the dimensions of the motor pedestal, and
the distance between the coupling center and the motor shaft ends.
3. Before rotating, set the initial value to zero.
4. Turning both the motor shaft and the reducer shaft to 60o-75o.
5. Both the angular deviation δz and the radial deviation δy will be shown on the panel. The accuracy of
the readings will be up to 1μm.
6. The microcomputer will automatically calculate the value of displacement of the motor and the
difference of the shim thickness which are advantageous for an operator to re-align the motor. The
microcomputer has memory and printing function.
7. Add or reduce the shims to decrease the deviation in vertical direction; adjust the fitting bolts or blocks
for motor pedestal to decrease the deviation in horizontal direction.
8. Repeat step 2~7 until the deviation meets the standard.

4.5.2 Inspect the alignment with a dial indicator

Figure 31 shows the alignment measure method with a dial indicator.

Figure 31. The measure method with a dial indicator

© ZPMC 2016. All rights reserved. Revision: A

16
 RTG Mechanical Maintenance Manual

1. The indicator base is set on the shaft face of inner half-coupling and the finger contacts the other one.
2. Initially, set the reading to zero. Suppose that the starting point is 0°, then it reads the values of δ90°,
δ180° and δ270°, after the coupling rotates 270° (note the positive and negative signs). The
circumferential jumping value in the vertical direction is Δry=δ180°/2.
3. The circumferential jumping value along the horizontal central line is ΔrZ=δ90°-δ270°. The maximum
circumferential jumping value is Δr= Δry2 + Δrz2 .
4. Similar as shown in the document, make the finger contact the end face of the other half-coupling or
surface of the brake dick and adjust the value to zero. After turning 270°, it can reads the values of δ90°,
δ180° and δ270°. And Δay= δ180°，Δay= δ90°-δ270°. Then Δby=arctgΔay/r，Δbz=arctgΔaz/r.
5. You can estimate the thickness of shims under the motor pedestal and the translation in horizontal
direction by Δry and Δrx. You can also estimate circumrotation in direction Y (the deviation of thickness
between the front and back shims) as well as the circumrotation in direction X (the deviation of
thickness between the left and right shims) by Δa and Δb. Refer to 4.5.1.1 step 7 and adjust the
estate of motor to meet the standard.

4.5.3 Adjustment methods of alignment for drum coupling

1. The indicator base is placed on one side of the coupling and the finger contacts the outer ring of the
other side of the coupling. Refer to Figure 32.

Figure 32. Inspect alignment of low-speed coupling with dial indicator

2. Initially, set the reading to zero. So it can reads δx180°after rotating 270°. (Note the positive and
negative signs).
3. Survey the radius of measure-point.
4. Make the finger contact the end surface of the other coupling or surface of the brake dick, and adjust
the value to zero. After turning 270°, it can read the values of δ90°, δ180° and δ270°. And Δay=δ180°- δ270°,
Δaz=δ90°- δ270°, then Δby=arctg Δay / r, Δbz=arctg Δaz / r.
5. Adjust the thickness of the shims under the drum bearing pedestal and the bearing pedestal’s position
to meet the standard.
6. The drums are supported by the low-speed shaft of reducer and in the center of it, so there are only
angular deviation and axial deviation, no radial deviation.

© ZPMC 2016. All rights reserved. Revision: A

17
 RTG Mechanical Maintenance Manual

4.5.4 Alignment of brake­disc

1. Inspect the height of the brake to align its central line with the brake disc center. The deviation should
not be more than 2mm. The horizontal deviation of the brake lining from the edge of disc should not be
more than 5mm. Refer to Figure 33.

Figure 33. Center bias of brake

2. Inspect the position of the brake base in the motor axial direction. The deviation of the central line of
disc thickness should not be more than 0.5mm.
3. When the brake is open, the clearances between the two brake linings and disc should be the same.
δ1= δ2=1~1.5mm. Refer to Figure 34.
4. δ1and δ2 should not be less than the minimum value of 1mm set for the brake. Refer to Figure 34 .
5. The up and down clearance of brake disk should be the same, which means δ1up= δ1down, δ2up= δ2down.
Refer to Figure 34.

Figure 34. Clearance excursion of brake

6. The contact area between the linings and the disc should not be less than 70% when brake is closed.

© ZPMC 2016. All rights reserved. Revision: A

18
 RTG Mechanical Maintenance Manual

4.6 Lubrication

4.6.1 Summarization

Lubrication is a very important maintenance task. It will determine the normal service and endurance life of
the components. Proper lubrication practice will help to avoid premature wear and extend the endurance
life of the components. Lack of lubrication will destroy the components. For example, if an anti-friction
bearing is short of lubrication, it will be damaged in a very short time. It is very important to monitor the
temperature and sound level of the components to determine whether the components get enough
lubrication. The lubrication of wire rope will be described in Chapter 6.

CAUTION

Collect and dispose all used oil and grease properly!

4.6.2 Lubricant

For well effect of lubrication, the type of lubricants must be selected properly. Maintain consistency on
lubricants. Do not mix up different lubricants together. If the lubricant supplier, type or grade is changed,
clean the bearing, reducer, pin, and other devices thoroughly to remove the previous lubricant. If different
lubricants are mixed together, please contact the lubricants supplier.

The lubricants and grease used in the crane are listed in Table 4- 8~Table 4- 10. And the comparison of
those products is also listed in the tables.

NOTE: The brand underlined is the oil used when delivery.

Table 4- 8. Gear Box Oil (please ref. to the gear reducer manual)

ISO(40 ºC, MM2/S ) NAME AND CODE NAME °C °C PLACE CODE

POUR FLASH NAME
POINT POINT

ISO 220 GB5093­95 L­CKC -8 200 gantry

VG 220 Shell Omala -18 238 reducer
Shell Omala LPP* -27 210
Shell Omala HD -48 245 A1
Mobil Mobilgear 630 -24 240
Mobil Mobilgear XMP -24 272
Mobil Mobilgear SHC XMP -45 244

ISO 320 GB5093­95 L­CKC -8 200 Hoist

VG 320 Shell Omala -15 238 reducer, A2
Shell Omala LPP* -27 210 trolley
Shell Omala HD -45 242 reducer
Mobil Mobilgear 632 -18 265
Mobil Mobilgear XMP -18 268
Mobil Mobilgear SHC XMP -38 242

© ZPMC 2016. All rights reserved. Revision: A

19
 RTG Mechanical Maintenance Manual

NOTE: Lower temperature gearbox oil is for ZPMC special purpose use.

Table 4- 9. Hydraulic lubricants (detail please ref. to the Emergency brake pumping station
manual)

ISO(40 ºC, MM2/S ) NAME AND CODE NAME °C °C PLACE CODE

POUR FLASH NAME
POINT POINT

ISO 32 Shell Tellus -30 209 B1

VG 32 Shell Tellus T -42 242
Shell Tellus S -30 207
Mobil DTE 20 -27 220
Mobil DET 10M -45 210
Mobil DTE Excel -33 222

ISO 46 Shell Tellus -30 218 Emergency B2

VG 46 Shell Tellus T -39 246 brake
Shell Tellus S -30 218 pumping
Mobil DTE 20 -27 232 station
Mobil DET 10M -42 216
Mobil DTE Excel -33 226

Table 4- 10. Grease

NLGI NAME AND CODE NAME °C WORK PLACE CODE

CLASS POUR TEMPERATURE NAME
POINT °C

- S Lithium based GB7324­94 175 -20~+120 Heavy Duty Bearing C1

1 grease No.2 185 -20~+100 Grease/ Equalizer
1 shell Alvania EP1 190 -25~+120 hinge point/ Open
Mobil Mobilux EP 1 Gear/ chain

- Lithium based GB7324­94 175 -20~+120 Wire rope C2

- grease No.2 90 -10~+60
1 Synthetic calcium SH/T0372-95 185 -20~+100
- based grease No.3 190 -25~+120
1 Shell Alvania EP1
Shell Malleus GL
Mobil Mobilux EP 1

© ZPMC 2016. All rights reserved. Revision: A

20
 RTG Mechanical Maintenance Manual

NLGI NAME AND CODE NAME °C WORK PLACE CODE

CLASS POUR TEMPERATURE NAME
POINT °C

1 Shell Alvania RL1 180 -30~+120 High speed bearing/ C3

2 Mobil Mobil Polyrex 288 Electric Motor
EM Bearings Grease(ref.
to the motor manual)

4.6.3 Lubricant replacement standard

The deterioration of the lubricant lies on the work frequency and the ambience.

In inspection of the lubrication or in the use of lubrication, replace the lubricant whenever sizable quantities
of any of the following conditions are found:

1. Rubber-like deterioration
2. Impurity
3. Metal powder and badly discoloring
4. Emulsification
5. Separation of mineral oil and saponification radicel (deterioration due to oxidation).

In addition, determine whether the lubricant needs to be replaced by periodical oil sample test: take
approximate 20 milliliters of lubricant from the machine and consult the lubricant manufacturer or deliver it
to lab to check .The detail of standard is listed in Table 4- 11, replace lubricant or append additives
according to the test result if any standard is met. Refer to sampling program to Section 4.6.5.

Table 4- 11. The standard of lubricant replacement

THE STANDARD OF
TEST ITEMS TEST METHOD
REPLACEMENT

Kinematics viscosity variety (40oC) Increase 15% or decrease 20% ASTM D 445

Acid number Decrease 35% or increase ASTM D 974

≥0.4mgKOH/g

Normal heptane thawless ≥0.1% IP 316

Sheet copper erodibility Less than Grade 2a ASTM D 130

Chroma variety Chroma ≥2 than new lubricant ASTM D 1500

Humidity ≥0.1% ASTM D 1744

4.6.4 Lubrication procedure

1. When the reducer oil is changed, drain the used oil while it is still warm. Clean the tank floor with oil to
remove deposit, metallic particles and oil residue. Use the same type of oil to keep normal operation.
2. When re-lubricated bearings, pump the new grease into the oil pocket through grease fitting. Clean out

© ZPMC 2016. All rights reserved. Revision: A

21
 RTG Mechanical Maintenance Manual

the old extruded grease after re-lubrication. After the first shift of operation after re-lubrication, clean the
lubricating points.
3. For lubricating motor, emergency brake, reducer and other outsourcing parts, please refer to their
manuals.
4. Wire ropes should be under good lubrication condition at any time. Lubricating will prevent the wire
rope from corrosion and reduce the friction in rope strands, between the wire ropes and the sheaves
and/or drums. The type of lubricant and application frequency varies with the rope construction, the
operating conditions and its functional application. .
5. The quantity of oil/grease should be suitable.
6. For gear reducers (splash lubrication), the oil level should be kept a little higher than the central level
between the highest and lowest levels because the oil level will become lower when the gear reducer is
working.
7. For bearings and other relatively sliding parts, it is natural that the old grease flows out of the seal from
one side when the new grease is pumped in from other side.
8. Oil and grease complementary cycle. It has relationship with the ambience, sealing condition, working
grade and operating frequency of each part.
9. For reducers not used frequently, bottom valves should be opened periodically to inspect the moisture
content of the oil.
10. At the early stage of the crane’s operation, collect three samples from the replaced old oil to analyze
the percentage of metal powder in it. Compare and analyze the lubricant to find out the working status
of machine.

4.6.5 Lubrication analyzing and monitoring

An effective oil conditioning and monitoring program can help extend the equipment life, reduce scheduled
and unscheduled downtime, reduce maintenance costs and extend lubricant change intervals.

The condition of oil is very important for proper operation of a device. Take a sample for each component in
the table below at least once a year and analyze the sample at least from the following aspects:

1. Kinematical Viscosity
2. Particle Count
3. Moisture content inspected by Karl Fisher
4. Metal grains inspected by Spectroscopic

4.6.5.1 Basic principles of sampling of lubricant

1. Take the sample from the same point every time.

2. Take the sample from the machine used recently and at the time when the temperature of lubricant is
close to working temperature.
3. Take the sample from the lower reaches of working group. Refer to Figure 35.

© ZPMC 2016. All rights reserved. Revision: A

22
 RTG Mechanical Maintenance Manual

Figure 35. Step 1

4. Don’t sample from the points listed below:

 Where there is only a little lubricant or lubricant is not ambulatory.
 Where remnant and water conglomerating (for example, in the relief valve)
 The end of blind-tube
 The lower reaches of filter
 The drainage valve on the bottom of the tank
5. Don’t sample while the lubricant has just been changed.
6. Keep clean of the sampling tool (dry, no remnant).

4.6.5.2 Sampling tool in common use

Figure 36. Sampling tool

© ZPMC 2016. All rights reserved. Revision: A

23
 RTG Mechanical Maintenance Manual

1. Sampling bottle 3. Sampling pump

2. Sampling canal 4. Sample label / sampling point label

4.6.5.3 The steps of sampling

Figure 37. Steps

1. Take off the cover of a clean, dry sampling bottle and screw the bottle into the pump
2. Shear the ends of a new section of pipe to 45 degree.
3. Put the pipe in the pump from the top until the pipe into the bottle, and then fasten the screw to fix the
pipe.
4. Put the end of the pipe into the sampling point, keep the bottle upward. Absorb the lubricant to the
bottle with the pump, and remain 25mm air clearance.
5. Screw off bottle and put the cover back to the bottle instantly to avoid pollution.
6. Fill in the sampling label clearly and stick it to the sampling bottle. The collection of lubricant is
completed.

Figure 38. Label

NOTE: Oil sample analysis is an active maintenance method, which can be used to
monitor the operation condition of grease and machine.

© ZPMC 2016. All rights reserved. Revision: A

24
 RTG Mechanical Maintenance Manual

4.6.6 Lubricating points layout

Figure 39 and Figure 40 gives the assembly to be lubricated, the amount of lubricating points and the style
of bearing at lubricating point. There are relationship between the figures and Table 4- 12.

Figure 39. Gantry lubricating points layout

© ZPMC 2016. All rights reserved. Revision: A

25
 RTG Mechanical Maintenance Manual

Figure 40. Trolley lubricating points layout

4.6.7 Lubricating frequency

The lubricants and lubricating frequency are listed in Table 4- 12. Lubricating frequency has relationship
with the weather such as temperature and rainfall, and the service condition of the crane at the terminal.
The lubricating frequency listed in the table can be used in common condition. The maintenance people
should observe whether the lubricating is enough during the cranes service, to prolong or shorten the
lubricating periods properly. Refer to Figure 39 and Figure 40 while using the table

© ZPMC 2016. All rights reserved. Revision: A

26
 RTG Mechanical Maintenance Manual

NOTE: The lubricating frequency listed is based on ZPMC’s experience and common
condition. Please keep an intact note or log. Based on the maintenance note, you can
redefine and change the lubricating frequency in the case of well lubricating condition.

NOTE: The interval of lubrication is at most 3 years commonly. After this period,
change the lubrication even if the lubrication is not metamorphosed. Refer to the
lubrication suppliers’ recommendation.

NOTE: Sample the hydraulic oil and gear lubrication while the recommended replacing
period listed in Table 4- 12 is reached. If the sample shows that the lubrication needn’t
be changed, the lubrication can be used while monitoring should be reinforced. What’s
more, you should sample the gear lubrication every 2 years even if the replacing
period is not reached.

NOTE: The lubrication of forestay is very important for keeping well working status. If
there is rust on the friction surface between the pin and stay bar, appended bending
moment will be engendered in the stay bar while it is turning, and flaw can be
engendered and expanded. So remove ancient grease and add new grease every
month.

Table 4- 12. Lubricating frequency

SYMBOL

D Daily 3M Every three month or ～1000 hours

W Weekly 6M Every six month or ～2000 hours

M Monthly ～or 300 hours A Annually or ～4000 hours

H According to working time (hour)or else

ABBREVIATION OF LUBRICATION REFER TO TABLE 4­ 8 TABLE 4­ 10

A1 ISO VG 320 A2 Mobil SHC 632

B1 ISO VG 32 B2 ISO VG 46

C1 EP 2 C2 Chesterton

C3 Mobile(refer to supplier)

ABBREVIATION OF LUBRICATION POINTS TYPES:

Ⅰ Hydraulic Ⅱ Gear

© ZPMC 2016. All rights reserved. Revision: A

27
 RTG Mechanical Maintenance Manual

SYMBOL

Ⅲ Common anti-friction Bearing Ⅳ Motor Bearing

Ⅴ Sliding Bearing Ⅵ Chain drive

Ⅶ Gear Coupling or Spline Ⅷ Wire Rope

Ⅸ Others such as spring, seal…

CAUTION

Refer to drawing / correlative independent part maintenance manual.

LUBRI
PERIOD LUBRICATION AMO
CANT
NO. POINT STYLE / UNT/ REFERENCE
(CODE
REMARK RTG
D W M 3M 6M A H NAME)

1 ● C1 Gantry wheel shaft 16

support

2 ● A1 Gantry reducer 4 Refer to reducer

maintenance manual

3 ● C1 Equalizer 32
pin/slewing
bearing/steering
system

4 ● C1 Chain/ reducer 20
bearing/pin

5 ● C3 Gantry motor 4 Refer to motor

maintenance manual

6 ● A2 Main hoist reducer / 3 Refer to reducer

trolley reducer maintenance manual

7 ● B1 Brake 2 Refer to brake

maintenance manual

8 ● C1 Sheave/trolley 29
wheel/drum bearing
support/side
roller/floating frame

© ZPMC 2016. All rights reserved. Revision: A

28