Document No.

: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

Week: Date :
QC : Control on hours :
Service Part/consumable
No Location Task name Description Man hours Tools Date Status Remark
instruction Name Q'ty
1 - A FRAME LOCATION

Check Limit Visual Check condition

1
Switch inspection of all limit switch

Check condition
Visual
2 Boom sheave and lubricate for
inspection Boom sheaves

2 - BACK REACH LOCATION

Check function &

wiring of trolley
Check Limit Operating
1 reverse stop and
Switch inspection end stop limit
switch

Check and
clean limit
Check Limit Visual
2
Switch
switch and
inspection
proximity
switch

Check motor,hyd
Check motor, pump,coupling :n
hyd oisy,vibration,te
pump,coupling mperature and
tighten

Operating
Normal correct
inspection pressure :
TLS : P =
Check hyd
14MPa
pressure
Trolley : P =
(indicator)
9MPa
Cat- trolley : P =
7MPa

Check for
3 Hydraulic
component
 Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

Check for Replacement

3 Hydraulic hyd oil for first
component Replacement 500hrs ( 500L
hyd oil ISO VG68)
Clean out
Replacement hydraulic tank

Replacement
Replacement hyd filter and
hyd filter return filter for
first 500hrs

Operating Check hyd oil

inspection level,oil leakage

Check and
Visual tighten hose
inspection hyd ,bolt
connection

Check rope
tensioner,TLS
hydraulic system
Visual and condition of
4 TLS Systems cylinder
inspection
Check and
tighten bolt
connection

Operating Check condition Visual , listening

inspection of Sheaves during operation

Check sheaves
5 Check &
condition
lubricate for Check sheave
Visual
Hoist,Trolley,Cat condition and
inspection -trolley sheaves' grease
bearing
 Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

Check supported
cable and
festoon trolley
support for any
damage

Check for any

Visual
rollers, and
inspection wheels missing

Check festoon
cable clamp for
loosing
Check and
tighten bolt
connection

Check festoon
6
systems Verify that the
trolley is
running parallel
to the trolley
rails without
binding on
either side
wheel flanges.
Operating Trolley
Verify that
inspection alignment
water side
trolley tow
cables are
equal length
and are towing
the trolley
square with the
crane.

Festoon truck Check the

side guide trolley side
rollers. rollers for wear
Visual
7 Festoon truck
inspection
 Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

Visual
7 Festoon truck
inspection
Festoon truck Check the
main support trolley main
rollers. rollers for wear

3 - BOOM LOCATION

Check condition
Boom anti- Visual Check wire rope
1 boom anti-
colision inspection loose ,rust,…
collision

Pick up control
power, then
manually
active one of
Check the ship the proximity
Boom anti-
Operating collision wire switches. The
2 colision limit
switch inspection and limit control power
switches should lose.
Reset and
verify the
remaining limit
switches.

Check Lighting
Visual
3 Check lighting and aviation for
inspection proper operation

Check condition
and lubricate for Check sheave
Check boom tip Operating
4 Boom,Hoist,Troll condition and
sheaves inspection ey,Cat-trolley grease
sheaves

Check the
main hoist rope
Main hoist wire wedge clamp
Boom tip - Visual
5
Hoist wire rope
rope dead end tightness.
inspection
connection. Verify no
slippage has
taken place.
 Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

When Boom
Check condition
Operating operation verify
6 Boom hinge of Boom hinge
inspection and grease have noisy
abnormal

Clear trolley
Check condition home position,
and function of
All local limit Operating then move
7 trolley parking
switch inspection the trolley to
position limit
switch cross the
switch

4 - ELECTRIC HOUSE
Check function
Visual
1 Air-conditioner of Electrical
inspection room A/C

Check PLC
wiring &
connection (to
be executed firs
Visual at time on all the
2 PLC room
inspection termination in
the E-House ,
then periodically
every 3 to 6
months )

Verify the
Verify functions
function lights
Instrument Operating and indicating
3
indication
of instrument
inspection lights in the E-
indications in
room
the e-room

Clean all the

Visual
debris from the
inspection
electric room
4 Electric house
 Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

4 Electric house
Contacting
Visual condition of
inspection relay and
contactor
5 - MACHINERY HOUSE LOCATION

Boom motor, Check Boom

Operating reducer, drum abnormal
inspection coupling and noise ,vibration
1 Boom drive drum bearing and temperature

Check and
Visual
grease Boom
inspection
coupling,drum
Replacement
reducer oil for
first 500hrs
Replacement
Replacement (700L ISO
reducer oil
VG220)
2 Boom reducer Clean out
reducer

Check Boom
Visual
reducer oil
inspection level,oil leakage

Check wear and

damage for Normal
Visual
boom hoist thickness brake
inspection brake and brake lining > 6mm
parts
Boom thruster
3
brake Check brake
torque setting
Visual and reserve
Normal 4620Nm
inspection stroke of Boom
high speed
brake

Check and
adjust Boom See ZPMC
Visual
4 Boom brake high speed brake manual
inspection
brake and low adjustment.
speed brake
 Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

Check the
emergency
brake disc
surface.Make
sure that no
Check and clean
Boom brake Visual grease and
5 out surface
disc inspection debris are on
brake disc
the surface of
the disc.Clean
with solvent
and repair as
required.

Check Boom
Visual
wire rope Tighten bolts
inspection
clamp tight

6 Boom wire rope Check

Operating condition and check and lub
wire rope when
inspection lubricate Boom Boom moving
wire rope

Hoist motor, Check Hoist

Operating reducer, drum abnormal
inspection coupling and noise ,vibration
7 Hoist drive drum bearing and temperature

Check and
Visual
grease Hoist
inspection
coupling,drum
Replacement
reducer oil for
first 500hrs
Replacement
Replacement (500L ISO
reducer oil
VG320)
8 Hoist reducer Clean out
reducer
 Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
8 Hoist reducer
Page: 1 of 1

Check main
Visual
hoist reducer oil
inspection level,oil leakage

Check wear and

Normal
Visual damage for main
thickness brake
inspection hoist brake and
lining > 6mm
brake parts
Hoist thruster
9
brake Check brake
torque setting
Visual and reserve Normal 20700
inspection stroke of Hoist Nm
high speed
brake

Check and See ZPMC

Visual adjust Hoist high
10 Hoist brake
speed brake and
brake manual
inspection
low speed brake adjustment.

Check the
emergency
brake disc
surface.Make
sure that no
Check and clean
Hoist brake Visual grease and
11 out surface hoist
disc inspection debris are on
brake disc
the surface of
the disc.Clean
with solvent
and repair as
required.

Check Hoist
Visual
wire rope Tighten bolts
inspection
clamp tight

12 Hoist wire rope

 Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

12 Hoist wire rope Check check and lub

Operating condition and wire rope while
inspection lubricate Hoist trolley ,hoist
wire rope moving

Trolley motor, Check Trolley

Operating reducer, drum abnormal
inspection coupling and noise ,vibration
13 Trolley drive drum bearing and temperature

Check and
Visual
grease Trolley
inspection
coupling,drum
Replacement
reducer oil for
first 500hrs
Replacement
Replacement (250L ISO
reducer oil
VG320)
14 Trolley reducer Clean out
reducer

Check Trolley
Visual
reducer oil
inspection level,oil leakage

Check brake
torque setting
Visual
and reserve Normal 3740 Nm
inspection stroke of Trolley
brake

15 Trolley brake Check wear and

Normal
Visual damage for
thickness brake
inspection trolley brake and
lining > 6mm
brake parts

Check and See ZPMC

Visual
adjust Trolley brake manual
inspection brake adjustment.
 Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

Check the
emergency
brake disc
surface.Make
sure that no
Check and clean
Trolley brake Visual grease and
16 out surface
disc inspection trolley brake disc debris are on
the surface of
the disc.Clean
with solvent
and repair as
required.

Check Trolley
Visual
wire rope Tighten bolts
inspection
clamp tight
Trolley wire Check
17
rope condition and check and lub
Operating
lubricate wire rope while
inspection trolley moving
Trolley wire
rope

Check motor,hyd
pump,coupling :n
Operating Check motor,hyd
oisy,vibration,te
inspection pump,coupling
mperature and
tighten

Check hyd Normal correct

Operating
pressure pressure P =
inspection (indicator) 14MPa
Hydraulic
component for Replacement
18 Boom/Hoist hyd oil for first
emergency Replacement 500hrs ( 180L
brake systems hyd oil ISO VG68)
Clean out
Replacement hydraulic tank

Replacement
Replacement hyd filter and
hyd filter return filter for
first 500hrs
 brake systems
Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

Visual Check hyd oil

inspection level,oil leakage

Motors are to
Inspect AC
be kept clean
motors for
and ventilating
cleanliness
openings clear

When the
Visual crimped
19 AC motor Inspect the marker
inspection
condition of the approaches
AC motor entry into the
brushes, brush holder,
replace the brush
worn ones replacement
should be
investigated.

Turn on the
Check switches.
machinery Replace the
Operating
20 Lighting house fluorescent
inspection
fluorescent light tubes that
lights don't work
anymore.

Check function
Machinery Operating Switch on the
21
house fan
of machinery
inspection fan in e-room
house fans

Clean all the

Machinery Visual debris from the
22
house inspection machinery
house.
6 - TROLLEY PLATFORM
 Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

Check
Grease for
condition ,lubrica
Trolley
Operating te for Trolley
1 Lubricate wheels,roller ,hoi
inspection wheels,roller ,hoi
st sheave, side
st sheave, side
rollers
rollers

When hoist up
Spreader cable
and down check
Operating reel motor,
abnormal
inspection reducer,
noise ,vibration
coupling
and temperature

Replacement
spreader cable
reel reducer oil
Replacement
for first 500hrs
Replacement spreader cable (90L ISO
reel reducer oil
Spreader cable VG220)
2
reel Clean out
reducer

Check spreader
reel reducer oil
level,oil leakage
Visual
inspection Check
spreader cable
reel's all Tighten bolts
screws for
tightness
Check and
Trolley wire Visual tighten trolley
3 Tighten bolts
rope inspection rope wedge
clamps
7 - CATENARY TROLLEY
 Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

Check condition
Check lubricate
and grease for
for Cat-Trolley
Operating Cat-Trolley
1 Lubricate wheels,
inspection wheels,
roller ,cat- trolley
roller ,cat- trolley
sheave
sheave

Wheels, Check condition

Operating check while
2 Rollers, of roller and
inspection trolley is moving
Sheaves sheave

Check the
Wheels,
Operating tightness of
2 Rollers, Tighten bolts
Sheaves inspection the sheave
support bolts

Check cat-trolley
Visual
wire rope dead
inspection end connection.

CAT - Trolley
3 Check
wire rope
condition and check and lub
Operating
lubricate wire rope while
inspection
catenary trolley trolley moving
wire rope

8 - GANTRY CABLE REEL

Check Gantry
cable reel
abnormal
Gantry cable reel
Operating noise ,vibration
motor, reducer,
inspection and
coupling )
temperature(mot
or, reducer,
coupling )

Check tighten
Operating
all cable reel
inspection
fastening bolts
Gantry cable
1
reel
 Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

Gantry cable
1
reel
Replacement
Gantry cable reel
Replacement reducer oil for
Replacement Gantry cable reel first 500hrs (50L
reducer oil ISO VG220)
Clean out
reducer

Check Gantry
Visual cable reel
inspection reducer oil
level,oil leakage

Check
Operating condition ,lubrica Grease cable
2 Guider
inspection te cable reel and reel and guider
guider

9 - GANTRY LOCATION

When gantry
Gantry motor,
moving check
Operating reducer,
Gantry abnormal
inspection coupling and
noise ,vibration
wheels
and temperature

Replacement Replacement
Gantry reducer Gantry reducer
1 Gantry drive Replacement oil for first oil for first
500hrs (75L ISO 500hrs (75L ISO
VG220) VG220)

Check Gantry
Visual
reducer oil
inspection level,oil leakage

Check and
Visual
tighten wheels Tighten bolts
inspection fastening bolts
 Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

Check brake
torque setting
Visual
and reserve Normal 200Nm
inspection stroke of Gantry
2 Gantry brake brake

Check and clean

Visual
out surface
inspection gantry brake disc

Check wear and

damage for
Normal
Visual gantry
thickness brake
inspection brake ,gantry
lining > 5mm
wheel brake and
2 Gantry brake brake parts

Check and See ZPMC

Visual adjust Gantry
brake ,gantry
brake manual
inspection
wheel brake adjustment.

Check motor,hyd
pump,coupling :n
Operating Check motor,hyd
oisy,vibration,te
inspection pump,coupling
mperature and
tighten

Check hyd Normal correct

Operating
pressure pressure P = 12
inspection (indicator) Mpa

Gantry wheel Replacement

3 brake hydralic hyd oil for first
sys Replacement 500hrs ( 180L
hyd oil ISO VG68)
Clean out
Replacement hydraulic tank

Replacement
Replacement hyd filter and
hyd filter return filter for
first 500hrs
 Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

Visual Check hyd oil

inspection level,oil leakage

Check the Set the

function of stowage pins,
Gantry stowage Operating
4
pin
gantry stowage then there is
inspection
pin limit no gantry
switches motion
10 - LIFTING SYSTEM

Check and
Check tighten electrical
Visual
condition ,positio wire termination
inspection n of limit switch and solenoid
valves

Remove
1 Headblock twistlocks out of
Clean &dye- Check cracks,
Headblock,
penetrant deformed,
clean by fuel,
checking abnormal
and dye-
penetrant test.

Tighten all
Visual
bolts on the Tighten bolts
inspection
head block.
Standing on the
Check condition
Operating head block and
2 Hoist sheave and lubricate of
inspection move hoist to
Hoist sheaves
check
11 - OPERATOR CABINET
 Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

Move trolley
near to the
over travel limit
switches,
Actuate the
over travel limit
switches
manually and
try to pickup
the control
power on, if
Verify trolley
the control
1 Drive over-travel limit
power can't be
switches
picked up, it is
ok. Select the
limit backup
switch in e-
room and pick
up control
power, and
verify
trolley motion
can be backed
up.

Check function
Clear hoist
of hoist home
home position,
and
2 Limit switch hoist all the
upper over
way up to hit
travel limit
the switch.
switches
 Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

Verify that
each motion
functions, its
readout is
approximately
correct, and
Trim, list and
3 TLS Systems that each
skew functions
home switch
brings the
respective
motion to
the home
position.

Check and
ensure all the
wiring
terminals in the
Wiring/
4
conduit
control panels,
consoles and
Genius
modules are
well tightened
 Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

Activate the
various
functions of the
masterswitch
and read the
reference from
PLC while
Check the
moving the
Seat/ function of
5
consoles
controller.
master
The functions
controllers
of each
motion, float
switch,
and each
thumb switch
are to be
verified.

12 - OTHER SYSTEM
Walk way Visual Check deform
1
structure inspection and damage

Operating Check condition

2 Lighting sys
inspection of lighting set

Warning Operating Check condition

3
horn/Light inspection of horn,light

Check condition
Maintenance Operating and all function
4
crane inspection of Maintenance
crane

Operating Check operation

5 Cooling fan
inspection of cooling fan
 Document No.: FM-TEC-003-000
Revision No.: 000
Effective Date: 12 DEC 2011
SUPPORTING DOCUMENT QC PREVENTATIVE MAINTENANCE 500HRS CHECK LIST
Page: 1 of 1

Check elevator
abnormal,
noise ,vibration
Operating and Grease general
6 Elevator
inspection temperature(mot elevator
or,
reducer,coupling
)

Note : MATERIAL REQUIRED : 40 kg grease EP2 , 30kg Grease Mobile Arma 789 , 1040L hyd oil ISO VG68 , 1440L ISO VG220 , 750L ISO VG320 ,10 kg
rags , 20 gloves
SPECIAL TOOLS REQUIRED : grease gun

MANPOWER : 5 persons