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Training g Instructions For KOJA RTG ZPMC

CHAPTER 1

General features of RTG Cranes ● Supported on 8 rubberrubber-tyred wheels ● Powered with a dieseldiesel-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: boxbox-section welded construction Trolleyy rail: clipped pp on the upper pp g girder Equalizer q beam: hinged g to the sill beam by yp pin 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

1.1 General layout of RTG

Figure 1.21.2-2 RTG crane trolley layout

1.1 General layout of RTG

As shown in Figure 1.21.2-1 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

1.1 General layout of RTG

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

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

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

Gantry travel speed

Remarks

1.2 Principal Technical Parameters of RTG D Description i ti

V l Value

Unit U it Degree

Spreader

slewing

±5

Di Diesel l engine

M d l Model

6LTAA8 9 G2 6LTAA8.9-G2

Power

220

BKw

Revolutions

1500

rpm

Model

MP-220-4A

Power

275

KVA

Revolutions

1500

rpm

Alternator

R Remarks k Cummins C i China

Marathon Shanghai

Lithium Battery Pack

16 Li-lon Battery Module Package

Number of containers stacked by the Crane

6

Container

Number of containers the Crane passes over

5

Container

440V,50HZ Sumitomo

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 noted t d. (7) Inspection of bolts shall comply with AISC Specification for Structural Joints Using (CHINA) GB1228-94 GB1228 94 10 10.9 9 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 following g 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 by y 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 perform f 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 according g 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 Each tyre can be rotated about its center by 90° 90° &16° &16 ° ● The bogie and equalizer beam connect by skew b i bearing ● Four vertical flangeflange-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 Description Gantry travel speed p A.C. motor ((with brake))

Reducer

Rubber tyres

Value

Unit

Only spreader

90

m/min

With rated load

25

m/min

Model

MVK8186D-FK

o e Power

22

kw

Revolutions

1670

rpm

Qty.

4

Model

FVS370.30.D1B

Reduction ratio

30.61

Input power

22

Qty.

4

Model

21.00-25,40ply

Diameter

1550

Inflation f pressure 980 Qty

4/8

Remarks

FUJI

ZPMC

kw ZPMC Samson

mm kPa

144psi (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 bearing g damage. g Check whether lubrication is correct. Lubricate in accordance with lubrication schedule . Period: routine

1.5.1.4 Inspection items and period for maintenance

((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

1.5.1.4 Inspection items and period for maintenance

((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

1.5.1.4 Inspection items and period for maintenance

(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”.

1.5.1.4 Inspection items and period for maintenance

((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

1.5.1.4 Inspection items and period for maintenance

((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.

1.5.1.4 Inspection items and period for maintenance

(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”.

1.5.1.4 Inspection items and period for maintenance

((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.

● Gantry

tyre replacement shall be carried out in no-wind weather condition. condition

● Consider

the following basic steps to accomplish the replacement:

1.5.1.5 How to replace gantry tyre

(1) Before replacement, preparation work shall be done such as various replacement parts(new tyre etc.) and required tools(two hydraulic jacks, electrical impact wrench h 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 p parked on one end of the g girder ((i.e.,, the end where the gantry wheels are not to be replaced).

1.5.1.5 How to replace gantry tyre

(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 equalizer li b beam with ith 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.

1.5.1.5 How to replace gantry tyre

(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.

1.5.1.5 How to replace gantry tyre

(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 p protection, p , cam ● Tachometer,, over speed 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 Description

Value

Unit

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 speed

with 35t load

22

m/min

empty spreader

55

m/min

Linear velocity of wire rope

with full load

44

m/min

empty spreader

110

m/min

The drum

Nominal diameter

980

mm

Num of groups Num. of grooves

4

Number of wraps of rope

3

pcs

Remarks

1.5.2.2 Table of Main Hoist Particulars Description Motor

Reducer

Value

Unit

Model

MVK931PB

Power

150

Kw

Revolutions

726/1814

rpm

Qty. Q y

1

Model

FH1210.51.C2A

Reduction ratio

50.774

Qty.

1

FUJI

ZPMC

YP31YP31-560x30 560x30--Ed1250 Ed1250--60 High Speed Model B k Brake Model of thruster ED1250 ED1250--60

Wire rope

Remarks

Braking torque

3550

Nm

Qty.

2

Model

IWRC 6xFi(29) 6xFi(29)--25 25--B

Diameter

Ø25

ZPMC ZPMC each brake KISWIRE

1 5 2 3 Main hoist wire rope reeving and its application 1.5.2.3

● Four F main i 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 rere-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

1.5.2.3 Main hoist wire rope reeving and its application

● 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

1.5.2.3 Main hoist wire rope reeving and its application

● 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 nonnon-operation of the Crane or after disassembly and rere-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 only l 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.

1.5.2.5 Inspection Items and Periods for Maintenance

(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 running g and then once per month all the bolts shall be inspected and rere-tightened. Special attention should be paid to those bolts which contribute to securing but is easily neglected Maintenance period: routine and once per month

1.5.2.5 Inspection Items and Periods for Maintenance

(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

1.5.2.5 Inspection Items and Periods for Maintenance

(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.

1.5.2.5 Inspection Items and Periods for Maintenance

(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”

1.5.2.5 Inspection Items and Periods for Maintenance

(5) Coupling ● Check whether the bolts are loosened loosened. Period: routine ● Check eccentricity and end run run--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

1.5.2.5 Inspection Items and Periods for Maintenance

(6) D Drum ● Check for loosening of the securing bolts. Period: routine ● Check Ch k whether h th wear off th the rope grooves exceeds limit value which is generally 20% wire i rope di diameter. t Period: once per month

1.5.2.5 Inspection Items and Periods for Maintenance

(7) AntiAnti-friction bearing (rolling bearing) ● Temperature rise shall not exceed 45° 45°C (in 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

1.5.2.5 Inspection Items and Periods for Maintenance

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

1.5.2.5 Inspection Items and Periods for Maintenance

(9) B Brake k di disc ● Check the disc surface for unevenness (convex(convex-concave) which should not exceed 0 0.3mm, 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

1.5.2.5 Inspection Items and Periods for Maintenance

(10) B Brake k ● Check that the brake action is maneuverable ● Check Ch k wear off the th b brake. 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

The following works are based on the safety rules.

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.

1.5.2.6 How to replace hoist wire rope

(3) Fi First, t cutt the th new ropes as which hi h llength th and d quantity according to the drawing’s requirement and d th then complete l t th the pressed d rope connector. t Otherwise, prepare some jute ropes which di diameter t about b t 20mm 20 and d wires i for f binding. bi di (4) To lower the spreader onto the ground and make it steady, y, then loosening g 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.

1.5.2.6 How to replace hoist wire rope

(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 and d 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 ground db by 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.

1.5.2.6 How to replace hoist wire rope

(7) U Using i jjute t ropes reeve th through h th the sheaves h according to the rope reeving system drawing and d bi binding di with ith th the 4 end d 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.

1.5.2.6 How to replace hoist wire rope

(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 ends d 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.

1.5.2.6 How to replace hoist wire 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 gravity y type yp L.S.,, wire rope, p , strike circle ● Consists of g 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 h hoist i t motion ti will ill 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

Traversing Speed

70

m/min

Motor (with brake)

Model

MVK8186B

Power

25

Kw

Revolutions

1700

Rpm

Qty.

1

Set

Model

YP11 YP11--ED220 ED220--50 50-315x20--IA 315x20

ZPMC

Model of thruster

ED220--50 ED220

ZPMC

Rated Braking torque

260

Nm

Setting Braking torque

220

Nm

Qty.

1

Set

Brake

Remark FUJI

1.5.4.2 Table of Trolley Traversing Particulars Description

Value

Unit

Traversing Speed

70

m/min

Reducer

Model

FH550.26.A2A

Reduction ratio

25.542

Input Power

25

Qty.

1

Di Diameter

500 00

Qty.

4

Wh l Wheels T ll R Trolley Railil

80 80 80x80

Remark ZPMC

Kw mm 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

The following works are based on the safety rules. 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 and d enclosed l d with ith warning line and caution.

1.5.4.6 How to replace trolley wheel and axle

(3) The crane is at non working condition and stay at a level ground ground, the trolley shall be parked and anchored at the middle of the girder， girder，lower the 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

1.5.4.6 How to replace trolley wheel and axle

Figure gu e 1.5.4.61.5.4.6 5 6 -1

1.5.4.6 How to replace trolley wheel and axle

(5) Dismantle the connecting bolt between the wheel assembly and trolley frame as show in figure 1.5.4.61.5.4.6 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 1.5.4.61.5.4.6-2(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.

1.5.4.6 How to replace trolley wheel and axle

Figure 1.5.4.6 1.5.4.6--2

1.5.4.6 How to replace trolley wheel and axle

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.

1.5.4.6 How to replace trolley wheel and axle

(8) Dismantle the wheel assembly, replace the old wheel and axle with new one one, reassembly the wheel assembly as per figure 1.5.4.61.5.4.6-3.

Figure 1.5.4.6 1.5.4.6--3

1.5.4.6 How to replace trolley wheel and axle

(9) Use U mobile bil crane tto h hoist 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 g girder 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.

1.5.5.1 Composition of horizontal wheel system

● 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.

1.5.5.1 Composition of horizontal wheel system

● 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.

1.5.5.1 Composition of horizontal wheel system

● 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.

1.5.5.1 Composition of horizontal wheel system

● 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 e electrical 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

(1) Oil (grease) supply During oil (grease) replacement the old oil (grease) shall h ll b be di discharged h d th thoroughly. hl G Grease shall h ll nott be mixed because mixed grease may result in bearing g damage g Period: routine (2) All parts and components Check bolts for loosening Period: routine and once per month 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 to t 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 swaysway-damping device

1.5.7.1 Composition of the swaysway-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 swaysway-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 sway sway. ● The motor winds up the slackened ropes, and the aboveabove-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 SwaySway 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 SwaySway y-damping p g (1) during spreader lowering Under the weight g 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 and d the h shaft h f iis revolving, l i and d the h tension i force in the swaysway-damping wire rope is the stall force of the torque motor. motor In this case swaysway-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 SwaySway-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. During g the trolley y running g ((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 - assembly y 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. (1) Oil (grease) supply During u go oil (g (grease) ease) replacement ep ace e t tthe eo old do oil (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

(2) All parts and components Check bolts for loosening Period: routine and once per month Check that lubrication is correct Lubrication shall be done in accordance with the lubrication schedule. Period: routine

1.5.7.5 Inspection items and period for maintenance

(3) Sheaves Check C heck 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

1.5.7.5 Inspection items and period for 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 YP21LZYP21LZ800--560X30 anti800 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

(1) All parts and components Check bolts for loosening Special the connecting bolts between trolley frame and cabin Period: routine and once per month (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 unit it 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.

1.5.9.3 Inspection Items and Period for Maintenance

● Make M k a record d off water t temperature, t t oilil pressure, etc. daily. ● The Th air i filter, filt lubrication l b i ti oilil filt filter and d 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, and d th the one cable bl end d iis fifixed d tto th the ttrolley, ll and d also l 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 E E--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 antianti-slipping. Platforms and ladders are painted painted, and the handrails handrails, stairs are hot dip galvanized. The stairs are connected with platforms through pins.

1.5.11.2 Inspection Items and Period for Maintenance

● Check bolts for loosening 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 bolts for loosening ● 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 ƒ

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(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 ƒ

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(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 wire e 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 ƒ

(8) Replace parts when they are worn to the permitted limit. ƒ (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 ƒ

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(10) After installation has been completed or after reretightening, loosening of some bolts in mechanical parts may result lt iin misalignment, i li t vibration, ib ti h heating, ti etc. t Th Thatt may cause reduction of service life of the corresponding components or may be the cause of running failure failure. (11) Routinely re - tighten bolts, nuts, etc.

2.2.1 Table of rere-tightening operation of bolts and d nuts t After 7 days

After 14 After 1 days month

After 3 month

After 6 After 1 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

Wire rope clamp bolts

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

0

0

0

Items above with marks “0” shall be inspected and re-tightened in the specified time interval

0

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: ƒ If there is a Crane nearby, the anti anti--collision device must be carefully inspected to prevent collision. ƒ During D i maintenance, i t iinspection ti or repairing i i a sign i ““under d Repair” shall be posted at a conspicuous place under the Crane C a e to op protect o ec pe personnel so e from o injury. ju y ƒ 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

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Confirming performance and ambient safety b f before operation. ti

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Observe the Crane’s condition and stop operation p after any y abnormal condition is found.

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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.

2.3.2.1 Routine Inspection Items

B f Before starting t ti operation ti Inspection Items 1.Obstruction within traveling range and the load traveling path 2. Obstruction on trolley rail track 3. Wire rope jumping off the drum or sheave or contact of the rope with any obstruction 4. Lack of lubrication in wire rope, strand breakage, loosening of clamp bolts 5. Inspection I i off brake b k pads d

Inspection Method Visual Visual Visual Visual Vi Visual l

2.3.2.1 Routine Inspection Items

B f Before starting t ti operation ti Inspection Items 6. Remedied condition of the defects found on previous day 7. Inspection of brakes 8. Various instrument panels and indicator lamps 9. Activation of various operation joysticks and button switches 10 A 10. Activation i i off major j lilimit i switches i h ((main i hoist, trolley, spreader)

Inspection Method Activation Starting Starting Starting S i Starting

2.3.2.1 Routine Inspection Items

D i operation During ti Inspection p Items 1. Abnormal sound, heating, vibration 2. Abnormal current, voltage 3 A 3. Activation ti ti off th the spreader d

Inspection p Method Visual Visual Vi Visual l

2.3.2.1 Routine Inspection Items

Aft Operation After O ti Inspection Items 1. Inspection of spreader 1.1 Deformation and fracture of base frame 1.2 Deformation and fracture of twistlock pins and flippers 1.3 Damage and torsion on spreader cable 1.4 Loosening of securing bolts

Inspection Method Visual Visual Visual Visual Visual

2.3.2.1 Routine Inspection Items

Aft Operation After O ti Inspection Items 2. If the various joysticks return to off position 3. If various bearings, gears and other lubricated parts are normal 4. Any abnormal heating 5. Any fracture or damage on various components 6. If the power switch is disconnected

Inspection Method Visual Activation Visual Visual Starting

2.3.2.1 Routine Inspection Items

Aft Operation After O ti Inspection Items 7. If power pack is switched off 8. If various components are clean 9. If the operator’s cab door is locked 10. Operation log and record of container handling for shift transferring

Inspection Method Visual Activation Visual Visual

2.3.2.1 Routine Inspection Items

It Items Inspected I t d per weekk Inspection Inspection Items Time After 1.Any loosening of bolts and damage operation of bearings 2. Any loosening of various pins, key boards and end stopper boards 3.Any torsion, damage, cracks of cable bl chain h i and d any lloosening, i corrosion of terminals 4 Activation of electro 4.Activation electro--magnetic contacts, knife switch, etc. The objective of this inspection is to find out defects between monthly inspections

Inspection Method Visual Visual Visual

Activation

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

Steel structu ure

Monthlyy Inspection p 1. Loosening of securing bolts

Annual Inspection p 1. Corrosion of steel

2. Fracture of welds 2. Peeling off of coating 3 Deformation 3. Deformation, fracture 3. 3 Wear of shafts, shafts pins of steel 4 Grease for shafts, 4. shafts pins 5. Loosening of bolts on stairs handrails, stairs, handrails platforms

2.3.2.2 Items Inspected p every y month,, every y year y

Trolle ey rail

Monthlyy Inspection p 1. fracture of welds

Annual Inspection p 1. Rail span

2 Loosening of 2. fixing bolts 3. Rail end wear and sinking

2 Elevation difference between 2. the two rails 3. Bending in vertical direction g in horizontal direction 4. Bending 5.Slope 7 Damage and corrosion of end 7. bumpers 8. Damage and corrosion of rail

2.3.2.2 Items Inspected p every y month,, every y year y

gearin ng

Monthlyy Inspection p 1.Abnormal noise, abnormal heating, abnormal vibration 2. Condition of teeth washing 3. Lubrication 4. Oil level, oil leakage 5. Loosening of securing bolts

Annual Inspection p 1. Cracks of casing

2. Loosening of the key 3. Deformation of the key slot 4. Contamination of oil

2.3.2.2 Items Inspected p every y month,, every y year y Bearing B gs

Monthly Inspection 1 Abnormal noise, 1. noise abnormal heating

Annual Inspection 1 Any cutting scrap in the oil 1. (grease)

2 Damage or 2. fracture of the body 3 Loosening of 3. securing bolts

2 Clearance between the pin and 2. bush 3 Wear of the bearing 3.

Sh haft

1. 1 Wear Wear, fracture 2. Loosening of the key 3 Deformation of the key way 3.

key

1. Deformation

2.3.2.2 Items Inspected p every y month,, every y year y Wheel W

Monthly Inspection 1 Wear 1. Wear, deformation of the tread surface

Annual Inspection

2 Bolts loosening 2. Drum m

1. Loosening of wire rope fixing 2. Damage to the wire rope guide 3. Damage to drum securing bolts 4. Fracture of welds

1. Wear on the rope groove

2.3.2.2 Items Inspected every month, every year Monthly Inspection

Annual Inspection

Sheav ves

1. Revolving condition 2 Fracture 2. 3. Rope groove wear 4. Damage to wire rope antianti-slipping device

Spreader S r

1 Deformation and fracture of the 1. base frame

1 Wear of the pins, 1. pins shafts etc etc.

2. Damage, deformation and wear of 2. PeelingPeeling-off of coating twistlock pins, flippers 3. Loosening of securing bolts 4 C 4. Center t tto center t off twistlocks t i tl k 5. Activation

3. Corrosion of steel

2.3.2.2 Items Inspected p every y month,, every y year y Grease supplyy G

Monthly Inspection 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

Annual Inspection

2.3.2.2 Items Inspected p every y month,, every y year y W rop Wire pe

Monthly Inspection 1 Broken wires in 1. strand 2 Wear and external 2. 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

Annual Inspection

2.3.2.3 Inspection Items after a storm After a storm or earthquake the Crane shall be inspected. I Inspection ti Items: It ƒ ƒ ƒ ƒ ƒ ƒ

(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?

2.3.2.3 Inspection Items after a storm ƒ ƒ ƒ ƒ ƒ ƒ

(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 dieseldiesel-alternator set normal? (11) Is insulation resistance value reduced? (12)Any damage to lighting fixtures

2.3.2.3 Inspection Items after a storm Points for Attention after Inspection: ƒ ƒ ƒ ƒ

(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

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(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 keep p them clean. Frequently q yg grease each sliding g 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 ƒ ƒ ƒ ƒ

(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 ƒ ƒ ƒ ƒ ƒ ƒ

(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 ƒ

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((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 type yp

Lubrication material

1

All wire ropes

Normally 1515-30 days

Follow the supplier’s requirement i t

Special wire rope lubrication oil

2

Main hoist reducer

Change oil after 400 hrs. of first running, then change oil every 5000hrs running

Oil bath

Refer to main hoist reducer manual.

3

Trolley reducer

Change oil after 400 hrs. of first running, then change oil every 5000hrs running g

Oil bath

Refer to trolley reducer manual.

Crane Lubrication Schedule No Description Lubrication period

Lubrication type yp

Lubrication material

4

Gantry reducer

Change oil after 400 hrs. of first running, then change h oilil every 5000h 5000hrs running

Oil bath

Refer to gantry reducer d manual.

5

g Rolling bearing and gear coupling

High g speed p end end:: once p per Grease month Low speed end end:: nipple 3 - 6 months

Industrial lithiumlithiumbased lubricant

6

Plain bearing

High speed end end:: once per day L Low speed d end end: d: once per week Add grease fully at each time of overhauling

Industrial lithium-lithium based lubricant

Operation temperature p higher than 50°°C 50

Crane Lubrication Schedule No Description

Lubrication period

Lubrication type yp

Lubrication material

7

Electrical Motors

Annual repair or overhaul

General motor i insulation l ti or tropicalized

Special motor lubrication

8

point p points Three months All p of brakes, limit switches, joysticks

Pins

HC 20 mechanical oil

9

Anti sway reducer

Change grease grease after first 100 hrs. running, then change oil every half a year y

Lithium Lithium---based based grease

Crane Lubrication Schedule No Description

Lubrication Lubrication period type yp

Lubrication material

10

Main hoist command limit, Open gearing, Hinged pin of universal coupling of the trolley, Gantry and antianti-sway open chain transmission

each month

Smear on surface

Lithium-Lithium-based grease

11

All sheaves’ shafts

three months th

Grease nipple i l

Lithium-Lithium-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 during g 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

2.6.1.1 Trouble in mechanical part 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.

2.6.1.1 Trouble in mechanical part 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 gp period 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.

2.6.1.1 Trouble in mechanical part 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..

2.6.1.1 Trouble in mechanical part 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.

2.6.1.1 Trouble in mechanical part p

● Sheave and Drum Since the wire rope has a fleet angle to the rope groove the rope g p g groove 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 and d 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 high g 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 rolling bearing

Lack of g grease or no grease

Add sufficient g grease

Contamination in the b i bearing

Clean the bearing with ith kkerosene and d fill with grease

Noise in rolling Poor installation bearing is increased misalignment of the bearing or over tightened and jammed Damaged or worn bearing elements

Check correctness of installation and adjust

Replace bearing

troubles and remedies Troubles

Causes

Remedy method

Periodic chattering g noise of the gearing in the reducer, particularly from the idle gear wheel

Excessive error of the teeth Remedy, y rerepitch. Teeth lateral assemble backlash exceeds standard value

reSharp friction sound and Clearance of gearing is too Remedy, reclatter 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 continuous knocking surface (laminated texture) sound heard from any point on the reducer casing and vibration of the reducer

Replace

troubles and remedies Troubles

Causes

g sound Knocking in the worm gear reducer, alternate high and low and the period coincides with that of gearing rotation sound

Excessive axial backlash Replace p of the worm or the teeth Repair or re re--assemble of worm gear are seriously worn, pitch circle of the gear is eccentric in relation to the shaft shaft, accumulated error of the circular pitch of the gear

Heating of the Lack of oil reducer

Remedy method

Oil temperature