NINE RUBBER-TYRED CONTAINER GANTRY CRANES

FOR

SUEZ CANAL CONTAINER TERMINAL

PORT SAID, EGYPT




User’s Manual & Maintenance Manual
(Mechanical Part)

SHANGHAI ZHENHUA HEAVY INDUSTRIES CO., LTD

May 2015
 PORT SAID, EGYPT 9 RTG PROJECT

TABLE OF CONTENTS
1. GENERAL .......................................................................................... 4

2. PRINCIPAL TECHNICAL PARAMETERS ............................................ 5

2.1. TABLE OF MAIN HOIST PARTICULARS .............................................................................................................6

2.2. TABLE OF TROLLEY TRAVERSING PARTICULARS ...........................................................................................7
2.3. TABLE OF GANTRY TRAVELING PARTICULARS ...............................................................................................7

3. POINTS FOR ATTENTION FOR SAFETY ............................................ 8

3.1. PREPARATION BEFORE CRANE STARTING. ................................................................................ 8

3.2. POINTS FOR ATTENTION AFTER OPERATION ............................................................................. 8
3.3. PARK THE CRANE AT THE ASSIGNED LOCATION. ....................................................................... 8

4. OPERATOR'S CAB .............................................................................. 8

5. STRUCTURAL PART ........................................................................... 9

5.1. GENERAL ............................................................................................................................... 9

5.2. MAJOR POINTS IN THE PAINTING PROCEDURE .......................................................................... 9
5.3. MAINTENANCE REQUIREMENTS ............................................................................................... 9

6. MAIN HOIST ..................................................................................... 10

6.1. DRIVE DEVICE ..................................................................................................................... 10

6.2. MAIN HOIST WIRE ROPE REEVING AND ITS APPLICATION. ........................................................ 10
6.3. POINTS FOR ATTENTION DURING OPERATION ........................................................................ 11
6.4. INSPECTION ITEMS AND PERIODS FOR MAINTENANCE ............................................................ 12

7. TROLLEY TRAVERSING ............................................................. 13

7.1. TROLLEY DRIVE MECHANISM ................................................................................................. 13
7.2. POINTS FOR ATTENTION DURING OPERATION ........................................................................ 14
7.3. HORIZONTAL WHEEL SYSTEM AND ITS ADJUSTMENT ................................................................ 14
7.4. PROTECTION OF THE TROLLEY .............................................................................................. 15
7.5. POINTS FOR ATTENTION DURING TROLLEY OPERATION ........................................................... 15

8. GANTRY TRAVELING ....................................................................... 15

User’s Manual and Maintenance Manual Page 1 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

8.1. COMPOSITION OF GANTRY TRAVELING MECHANISM ................................................................ 15

8.2. REPLACEMENT OF THE GANTRY WHEELS ................................................................................ 16
8.3. POINTS FOR ATTENTION IN OPERATION ................................................................................. 16
8.4. INSPECTION ITEMS AND PERIOD FOR MAINTENANCE ............................................................... 16

9. SPREADER SWAY-DAMPING DEVICE ..................................... 17

9.1. COMPOSITION OF SWAY-DAMPING DEVICE AND ITS FUNCTION ................................................ 17
9.2 POINTS FOR ATTENTION IN OPERATION .................................................................................. 17
9.3 INSPECTION ITEMS AND PERIOD FOR MAINTENANCE .............................................................. 17

10. THE POWER UNIT ............................................................................ 18

10.1. COMPOSITION OF THE POWER UNIT ...................................................................................... 18
10.2. POINTS FOR ATTENTION IN OPERATION ................................................................................. 18
10.3. INSPECTION ITEMS AND PERIOD FOR MAINTENANCE .............................................................. 18

11. ENERGY CHAIN SYSTEM ................................................................. 19

11.1. CONSTRUCTION AND PERFORMANCE ..................................................................................... 19
11.2. POINTS FOR ATTENTION FOR MAINTENANCE.......................................................................... 19

12. SPREADER AND HEADBLOCK ......................................................... 19

12.1. GENERAL ............................................................................................................................. 19
12.2. SPECIFICATIONS .......................................................................................................................
12.3. POINTS FOR ATTENTION FOR MAINTENANCE.......................................................................... 19
12.4. FOR DETAILS, REFER TO THE INSTRUCTIONS FOR THE SPREADER. ........................................... 19
12.5. INSPECTION ITEMS BEFORE OPERATION: ............................................................................... 19
12.6. IN CASE OF ACCIDENT ........................................................................................................... 20
12.7. PERIODIC MAINTENANCE...................................................................................................... 20

13. CRANE INSPECTION, MAINTENANCE AND REPAIR ....................... 21

13.1. CRANE TRAVEL OPERATION: ...............................................................................................................21
13.2. MANAGEMENT ............................................................................................................................................21
13.3. MAINTENANCE AND INSPECTION ..........................................................................................................22
13.4. PREPARATION OF THE CRANE ..............................................................................................................27
13.5. LUBRICATION OF THE CRANE ...............................................................................................................28
13.6. COMMON TROUBLES AND TROUBLESHOOTING FOR THE CRANE .............................................30
User’s Manual and Maintenance Manual Page 2 of 41
 PORT SAID, EGYPT 9 RTG PROJECT

Appendix 1-Manual of structural Part

User’s Manual and Maintenance Manual Page 3 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

User’s Manual and Maintenance Manual

(Mechanical Part)
1. General
The rubber-tyred gantry container crane is used for handling containers in
stack yards and for general cargo handling.

The Crane is supported on 16 (Sixteen) rubber-tyred wheels and powered

with a diesel-alternator set, which supplies power to every movement drive.
The Crane may move freely in the yard without the restrictions of trailing
cable or external power source. The crane is equipped with a telescopic
spreader, which is able to handle 20', 40', 45' and twin 20' standard
containers. The Crane is provided with a 8-rope sway-damping device to
reduce spreader sway and increase productivity. The Crane also has a
spreader slewing and micro-moving device at trolley and gantry travel
direction for easier spotting of the container. A 90-degree wheel turning
system together with a 360q crane rotating system allows ease of
movement.

The Crane is able to pass across 7(seven) rows of containers plus 1(one)
track lane, and to pass over 5(five) 40' containers 9' 6" high with 1(one) 9’6”
container lifted under the spreader.

The gantry frame of the Crane is of box-section welded construction. The

trolley rail tracks are welded on the upper girders. The equalizer beams are
connected to the sill beam through a hinged pin that is fixed with a keeper
board. Each equalizer beam has two bogie trucks and four wheels.

Constant power control is used for the main hoist; hoisting speed is
automatically adjusted depending on the load being lifted. The main hoist
has an overload protection device and overspeed protection to ensure safe
and efficient operation of the Crane.

The trolley traversing is provided with A.C. voltage regulation control. An

operator's cab is located under the trolley frame, and from there the
operator may operate the Crane. Four (4) trolley wheels are driven. That
ensures trolley traversing without slipping in any conditions; smooth starting
and braking are ensured for easier and accurate spotting.

The operator should thoroughly read these instructions and should be

specially trained in operation for three to six weeks. The container slots and
User’s Manual and Maintenance Manual Page 4 of 41
 PORT SAID, EGYPT 9 RTG PROJECT

lanes on the stack-yard should be designated with lines. The electrical

safety protection devices on the Crane should be adjusted properly.

For safety and protection the Crane has overload protection, diesel engine
overspeed protection, high water temperature and low oil (lubrication)
pressure signaling, anemometer, anti-collision devices for gantry traveling
located on four corners, emergency stop buttons, spreader load indicator,
limit switches for every movement and signal indicators, etc.

The Crane has lighting and signaling equipment for operation at night. The
gantry traveling is provided with alarms. For intercommunication between
the operator and the dock, the Crane has telephones, a public address
system and a radio speakerphone.

2. Principal Technical Parameters

Item Value Unit Remarks
Rated lifting capacity 50 t Under spreader
Exceptional lifting capacity 61 t Under spreader
Lifting height 18.25 m
exceptional load 11 m /min
Hoisting speed Rated load 22 m /min
Without load 50 m /min
Working Rated load 45 m /min
Gantry travel
Speed Spin turning 45 m /min
speed
Without load 135 m /min 0-17.7m/s wind
Trolley travel exceptional load 35 m /min
speed Rated load 70 m /min 0-17.7m/s wind
Span 26.5 m
Wheel Base 7.9 m
Total No. of wheels / No. of driven wheels 16/8 ps
Skewing f5e
Spreader
micromovement f200mm
Model TAD1642GE VOLVO
Diesel
Power 684 HP
Engine
Revolutions 1500 rpm
Model HCI 634K2 STAMFORD
400V, 50HZ,
Alternator Power 850 KVA
3-phase
Revolutions 1500 rpm

Row of containers stacked by the Crane 7 Container

Number of containers the Crane passes over 5 Container With one container

User’s Manual and Maintenance Manual Page 5 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

2.1. Table of Main Hoist Particulars

Description Value Unite Remarks
Number of wire ropes coming from the drum 8 ps
Multiple of rope reeving of sheave block 1
Rated lifting capacity (under spreader) 50 t
Exceptional lifting capacity 61 t
exceptional load 11 m /min
Hoisting Speed Rated load 22 m /min
Without load 50 m /min
exceptional load 11 m /min
Linear velocity of
Rated load 22 m /min
Wire rope
Without load 50 m /min
Nominal diameter ‡1200 mm
Number of groups of grooves on
8 groups
The the wire rope drum
drum Number of wraps of rope for fixing 2 wraps
Capacity of the drum
~380 m
(TOTAL)
Model 1PQ8-355 Siemens
Power 220 kW
Motor Revolution 735/1670 rpm
Voltage 400 V
Quantity 1 set
Model FH1650.125. ZPMC
Reducer Reduction ratio 125.315
Quantity 1 set
Model YP31A-710x30 ZPMC
Working Model of thruster ED2000-60
Brake Braking torque 7600 Nm
Quantity 1 set
Emerge Model ZPMC-SB315-2040x36 ZPMC
ncy Braking torque 188000 Nm
Brake Quantity 4 set
6XFi(29)-IWRC-B-Z
Model /JAPAN
lay
Diameter Ø30 mm
Wire
2x49 m
rope Outside
2x49 m
Length
2x46 m
Inside
2x46 m

User’s Manual and Maintenance Manual Page 6 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

2.2. Table of Trolley Traversing Particulars

Description Value Unite Remarks
Traversing exceptional load 35 m /min
Speed Rated load 70 m /min
Model 1LG4-188 Siemens
Power 17.5 kW
A.C motor Revolutions 1430 rpm
Voltage 400 V
Qnt'y 2 set
Model FH495.40 ZPMC
Reduction ratio 40.4
Reducer
Input Power 17.5 kW
Qnt'y 2 set
Model YP11 315x20 ZPMC
Model of thruster Ed220-50
Brake
Braking torque 260 Nm
Qnt’y 2 set
Diameter ‡630 mm
Wheels
Qnt'y 4 pcs
Rail track 80x80 mm Square steel

2.3. Table of Gantry Traveling Particulars

Description Value Unite Remarks
Gantry travel exceptional load 45 m /min
speed Spin turning 45 m /min
Without load 135 m /min
Model 1LP4-223 Siemens
Power 37.5 kW
A.C. motor Revolutions 1430 rpm
Voltage 400 V
Qnt'y 4 sets
Model QD313.45.12 ZPMC
Reduction ratio 45.43
Driving axle
Input power 37.5 kW
Qnt'y 4 sets
Model KFB63
Brake Braking torque 630 Nm
Qnt’y 4 set
Driven axle Model QDC1150 ZPMC

User’s Manual and Maintenance Manual Page 7 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

Model 16.00-25, 32PR

Effective diameter 1476 mm
Rubber tyres
Inflation pressure 10.0 kg/cm2
Qnt'y(driven/total) 8/16 pcs

3. Points for Attention for Safety

3.1. Preparation before Crane starting.
3.1.1. Check for obstructions in the Crane’s path.
3.1.2. Check that lubrication for every mechanical part is sufficient.
3.1.3. Check that every operation joystick and operation switch is in normal position.
3.1.4. Check that power supply voltage is normal.
3.1.5. A trial run without load should be done first and the running with load can be
started only after it is confirmed that various safety devices and limit switches are
activated normally.
Attention: Only authorized person is allowed to access the crane.
3.2. Points for Attention after Operation

3.3. Park the Crane at the assigned location.

3.3.1. Park the trolley at the stowed location, i.e., anchoring location.
3.3.2. Return all the operation joysticks and switches in the cab to neutral position and
specified position.
3.3.3. Check the rubber-tyred wheels.
3.3.4. If the Crane is not expected to be in use for a long period or a storm is forecast,
the crane tyres should be turned to the right position, and secured with chock racks.
3.3.5. Repair defects found during operation and confirm that all lubricants are correct for
the next operation.
3.3.6. Lock the doors of the operator's cab and electrical room to prevent unauthorized
entry.

4. Operator's cab
The operator's cab is attached to the extended support beam of the trolley frame
with bolts and cushioning pads.(the bolts can be maintained by dint of equipment
like liftcrane) The left side of the cab is connected with the towing support of the
Energy chain system. When the trolley traverses, it drags the chain and cable and
allows the operator a clear view of the container handling.

The operator's cab is 2.5m long and 2.2m wide and has window glass in front and
rear, and both sides as well as the front lower part of the cab. The glass is
electrical heating and laminated safety glass. The cab provides an excellent view
and has good natural light. The cab is spacious enough for easy cleaning. The
operator's seat is located in the front central part of the cab. The seat is designed
on the basis of ergonomics and is adjustable forward and backward, up and down.

User’s Manual and Maintenance Manual Page 8 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

The seat is cushioned and is soft and comfortable. The control console is on the
left and right hand sides in the cab. The backrest may be adjusted within wide-
angle ranges. Various electrical instruments and gauge, wind speed indicator, load
indicator and all operation instruments are arranged for convenient operation. The
operator's cab is provided with air conditioning, microphone, telephone and public
address system. All the windows can be cleaned from the inside except bottom
glass. The safeguard bars are fitted in front of the operator's seat and rear in case
of emergency braking.

5. Structural Part
5.1. General
The girders, gantry legs and sill beams of the Crane are of box-section
construction and the connections between them are welded. To avoid deflection
during shipment and erection both the supporting legs are connected with a stay
bar. Rail of square steel heavy type is fitted on the girder.

5.2. Major points in the painting procedure

All the plates are surface prepared to remove mill scales and then coated with
primer. After that the plates are cut and fitted-up and welded. After the structural
component is formed, it is post-treated (sandblasted). All the surface of the formed
components are coated with epoxy zinc-rich primer, intermediate and finished with
total dry film thickness greater than 240Pm.

5.3. Maintenance Requirements

5.3.1. Regularly inspect the trolley and the rail operation condition and if abnormal noise
is found check the trolley wheels and the shaft and keeper plate, etc.
5.3.2. Regularly check for deformation and welds of the trolley frame. Pay special
attention to the wheel shafts and take appropriate measures immediately after any
abnormal condition is found.
5.3.3. Frequently check the welds and the affected zone of the major members. Pay
attention to all support points and remedy defects immediately after they are found.
Check bolts for their tightening.
5.3.4. If a convex-concave surface is found on the box-section structure, the crane
should be stopped and the cause should be examined and removed.
5.3.5. Any damage to the paint on the structural members should be immediately
touched up.

User’s Manual and Maintenance Manual Page 9 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

6. Main Hoist
6.1. Drive Device
The drive mechanism of the main hoist is installed at the right part of the trolley
and consists of a motor, a high speed gear coupling, a gear reducer, a low speed
barrel type gear coupling between reducer and drum, two working brakes and
tachometer, overspeed protection, lift range protection, etc. The motor drives the
reducer through a barrel type gear coupling which drives the drum to wind up or
pay out the 8 sets of wire ropes which in turn lift or lower the spreader. The drum
gear coupling has a grease nipple fitting to grease it periodically and a drainage
hole is at 180 degrees opposite the fitting to discharge old grease. Wear of the
gear coupling should be inspected periodically. The working brakes are fitted on
the motor coupling. The motor coupling is not needed The brake disc should be
replaced if it is worn to the value equal to 30% of its thickness. The braking torque
of disc brake shall be greater than 2 times the motor torque.

The main hoist drum is made of plate steel with a nominal diameter of 1200 mm.
The drum is provided with eight (8) groups of grooves. One end of the drum is
connected to the reducer through barrel type coupling and the other end is
supported on the stub-through bearing that is seated on the trolley frame.

The main hoist is provided also with overspeed protection device that are located
at the rear part of the motor. The overspeed protection is activated when the motor
speed reaches 115% of its rated speed to stop main hoist movement. Limit
protection is fitted at the other end of the drum. This device provides the following
protection:
1) Stopping at upper lift end;
2) Stopping at lift lower end;
3) Slowing down before reaching upper and lower lift ends;
4) Stopping at lift upper extreme limit end.

6.2. Main hoist wire rope reeving and its application.

There are eight (8) main hoist wire ropes (from the end of the reducer) of 49m,
49m, 46m, 46m, 46m, 46m, 49m and 49m in length, and they are 6XFi(29)
IWRC B grade Z lay type with diameter of Ø30. The eight (8) ends of these ropes
are fixed on the drum through 3 clamps and bolts for each. The clamps are located
15 0 apart from each other and each clamp secures two wraps of the rope. The
clamp bolts are double end stud of M24, made from No.35 steel. Four pieces of
wire rope on drum go out from the drum bottom horizontally and pass across the
sheave blocks located on the trolley and then go downward to the headblock; The
other four go out from upper drum to sheaves. The whole arrangement is aim to
let the wire rope attach to the headblock as the same reverse triangle when you
look from each four direction of the trolley. This new reeving arrangement almost
realize the rigid connection between trolley to headblock and at the same time the
User’s Manual and Maintenance Manual Page 10 of 41
 PORT SAID, EGYPT 9 RTG PROJECT

extended angle of the wire rope is deeply enlarged which take the good role of
anti-sway. During reeving of the wire ropes the eight sets of wire rope shall be
tensioned equally. If uneven tension between them is found, the end securing
turnbuckles may be adjusted accordingly to make tensions between the ropes
evenly. After the first period of Crane running, the ropes must be re-adjusted
depending on their elongate. In normal operation uneven tension between the
eight sets of wire ropes shall be corrected immediately once it is found.

Attention shall frequently be paid to the fastening condition of the wire rope clamps
and the turnbuckle on the other end of rope, tighten the nuts if loosened.
Frequently check bolts of the clamp and turnbuckles, replace them immediately if
thread damage, cracks, etc. are found. The ropes shall not be twisted or knotted
during reeving.

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 or if the
diameter of the wire rope is reduced by 7% of its nominal size due to surface wear.
Pay attention to inspection for the rope jumping out of the sheave groove and if
there is any interference of the wire rope with other mechanical or structural parts.

Notes: For the eight wire ropes anti-sway, the requirement of the ropes adjusting
is high. The requirements are as bellows:
Spreader’s center and trolley’s center shall be in one straight line, i.e.
superposition. You can draw the center line of the gantry and trolley on the
ground, find the cross center of the spreader to verify the spreader’s center
superposition to the trolley’s center when it is on the ground.
Spreader’s cylinder shall be at zero position when adjusting the rope length by
turnbuckle. The four lifting spot of the spreader shall be in one height. Extend the
spreader to 40’ position, verify the spreader parallel to the gantry rail.
The out screw of the turnbuckle shouldn’t be too much (less than 50mm), the two
screw rods shall be set at least 80mm distance in order there is room for adjusting
after a period time running to compensating the rope’s elongate. The end of
turnbuckle has security bolt, shall be often inspected if it is bent or loose.
When the spreader up the ground, sway the ropes, inspect and contact if the
tightening condition of these eight ropes are same in order to prevent the load
cell’s display fluctuating and shortening some of the wire ropes’ life.

6.3. Points for Attention during Operation

After a long term of non-operation of the Crane or after disassembly and re-
assembly, the Crane shall be run first without load enabling the reducers,
bearings, etc. to be lubricated sufficiently and operation with load can be started
only it is confirmed that the running condition is normal.

User’s Manual and Maintenance Manual Page 11 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

6.4. Inspection Items and Periods for Maintenance

6.4.1. Oil (grease) supply
When the oil (grease) is to be replaced the old oil (grease) must be drained
thoroughly. Generally the lubrication oil (grease) shall not be mixed,
particularly the grease. Mixed grease may cause blockage that results in
bearing damage.
6.4.2. All parts and components
6.4.2.1. Check for loosening of fastening bolts
Frequently check for bolt loosening, especially one week after the
Crane’s first running and then once per month all the bolts shall be
inspected and re-tightened. Special attention should be paid to those
bolts that contribute to securing but are easily neglected.
Maintenance period: routine and once per month
6.4.2.2. Check that lubrication is correct.
Lubrication should be done in accordance with Lubrication Schedule.
Period: routine
6.4.3. Electrical Motors
6.4.3.1. Check temperature rise and overheating.
6.4.3.2. Check whether the bearing is abnormally heated.
6.4.3.3. Check for abnormal noise inside the motor.
6.4.3.4. Check the motor axial play that is generally controlled within 3 mm and max.
5mm. Excessive play may result in play along the tooth face width in the internal and
external gear ring of the gear coupling.
Maintenance period: routine
6.4.4. Gear reducer
6.4.4.1. Check that the oil is adequate by using the oil level indicator.
6.4.4.2. Check for oil leakage.
6.4.4.3. Is there any abnormal temperature rise? If the temperature is more than
50 degrees above the ambient temperature, the internal portion should be inspected.
6.4.4.4. Check for abnormal noise inside the reducer and disassemble and inspect if
any abnormal noise occurs.
6.4.4.5. Check connection bolts fastening
Maintenance period: all are routine
6.4.5. Coupling
6.4.5.1. Check whether the bolts are loosened. Period: routine
6.4.5.2. Check eccentricity and end run-out of the two halves of coupling.
6.4.5.3. Radial run-out must not exceed 0.10mm. Normally check once per year.
Period: routine
6.4.6. Drum
6.4.6.1. Check for loosening of the securing bolts.
Period: routine
6.4.6.2. Check whether wear of the rope grooves exceeds limit value that is generally
20% wire rope diameter.
Period: once per month

User’s Manual and Maintenance Manual Page 12 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

6.4.7. Anti - friction bearing (rolling bearing)

6.4.7.1. Temperature rise shall not exceed 50qC (in comparison with ambient
temperature).
6.4.7.2. Check for abnormal noise.
Period: routine
6.4.7.3. Check for loosening of connection bolts.
Period: routine
6.4.8. Encoder
6.4.8.1. Check whether the transmission is in good condition.
6.4.9. Brake disc
6.4.9.1. Check the disc surface for unevenness (convex-concave) that should not
exceed 0.3mm, and correct if necessary.
Period: once a month
6.4.9.2. Check whether wear exceeds limit and replace the disc when wear exceeds
30% of thickness.
Period: once per month
6.4.9.3. Check whether temperature rise is abnormal on surface.
Period: routine
6.4.9.4. Check whether the disc surface is damaged or contaminated with oil
(grease).
Period: routine
6.4.9.5. Check for fine cracks.
Period: routine
6.4.10. Brake
6.4.10.1. Check that the brake action is maneuverable
6.4.10.2. Check wear of the brake. The limit value is 3mm and replace if the limit is
exceeded.
6.4.10.3. Clearance at the brake shoe shall be kept to 0.5 -1.5mm.
6.4.10.4. Every pivot pin shall be frequently oiled. Frequently check wear of the pin
and matched hole.
Period: routine
6.4.11. Check the pulse signal transmitter for height indication
6.4.11.1. Check that gearing is in good condition
6.4.11.2. Check that pulse signal transmission is correct.
Period: routine

7. Trolley traversing
7.1. Trolley drive mechanism
The trolley drive mechanism includes two (2) electric motors that drive reducers through
couplings. The reducer in turn drives the wheels through 2 cardan shafts to propel the
trolley along the rails. The wheel system consists of wheels, wheel shafts supports,
bearings and sealing, etc. The wheel is attached to the wheel shaft through key
connection.

User’s Manual and Maintenance Manual Page 13 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

7.2. Points for Attention During Operation

To ensure normal operation of the trolley and reduce shock, careful inspection is needed.
7.2.1. Check that the noise in the reducer is normal, that the bearing is not overheated,
and that the oil level is correct .If any of these problems appear, the Crane should be
stopped immediately and the problem corrected.

7.2.2. Periodically check that the attachment of the wheel to its shaft is firm and if the
end fastening bolts are loosened. They should be tightened regularly.

7.2.3. Periodically check for wear on the trolley wheels since a difference in diameters
between wheels affects their synchronization. Wheels shall be replaced if their wear
reaches certain limit that may affect smoothness of traversing. If the wheels are found to
be worn rapidly, the cause must be found and removed. The diameters of the four
wheels shall be within the same tolerance.

7.2.4. When replacing the trolley wheels, first jack the trolley frame, remove the bolts on
the covers at two sides of the wheels. After that, roll the trolley wheel out of the trolley
frame along the rail track.

7.3. Horizontal wheel system and its adjustment

Horizontal wheels ensure that the trolley traverses along the rail tracks in a correct
way. The horizontal wheel system consists of supports, eccentric shafts, horizontal
wheels, etc. They are in two complete sets, fitted on appropriate horizontal wheel
supports. Horizontal wheels contact the side surface of the rail head to ensure the
trolley is aligned with the rail during traversing. Since a certain tolerance is
permitted for the rail installation, the eccentric shafts of horizontal wheels must be
adjusted to ensure the horizontal wheels pass through every section smoothly.
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 eccentric shafts.

Horizontal wheels are made from 42CrMo forged steel, quenched and tempered
and surface hardened to HRC50--56 with case depth t15mm that ensures wear-
resistance hardened tot HRC35. Horizontal wheels are subject to heavy shock
and frequent vibration, therefore, 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.

User’s Manual and Maintenance Manual Page 14 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

7.4. Protection of the trolley

7.4.1. Both (forward and backward) traverse end protection.
7.4.2. Both (forward and backward) end extreme limit protection.
7.4.3. Both (forward and backward) end slow down.
7.4.4. Trolley anchoring limit protection.
7.4.5. Bumpers 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.

7.5. Points for Attention during trolley operation

7.5.1. In case of abnormal noise during traversing it is necessary to check if the
horizontal wheels are loosened or dropped, etc.
7.5.2. 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.
7.5.3. 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.
7.5.4. 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.
7.5.5. Periodically grease every lubrication point to ensure normal lubrication.
7.5.6. For motors, reducers, couplings, etc. maintenance shall be the same as that for
the main hoist.

8. Gantry Traveling
8.1. Composition of gantry traveling mechanism
The gantry traveling has 16 rubber-inflated tyres divided in 8 sets; eight of the
tyres are driven and laid on each cornet of the crane. The other eight wheels are
idle. Each set of bogies is equipped with hydraulic wheel-rotating device and
locking pin. Through a lever system each tyred wheel can be rotated about its
center by 900 and rotate 3600 by the hydraulic device. This process must be
performed under non-operational conditions and at the assigned location. The lock
pin must be inserted into the slot to ensure smooth traveling .The bogie frame
rotating support is of slewing bearing type which are lubricated with grease. The
tyres are of 16.00 - 25, 32PR tubeless by ZPMC; the large wheel rim is of modified
and strengthened GQ-05H. The tyres have with external safeguard railings.

The traveling mechanism has 4 flange-mounted A.C. motors that drive 4

sets of gear reducers. In addition, the gantry traveling is provided with an
anti-collision device, telephone by which one can communicate with the
operator in the cab, acoustic and visual alarm for traveling, etc.
User’s Manual and Maintenance Manual Page 15 of 41
 PORT SAID, EGYPT 9 RTG PROJECT

8.2. Replacement of the gantry wheels

When the wheel or bearing or shaft is to be replaced or any support bracket is to
be repaired, this should be carried out in no-wind weather and preparation work
shall be done before hand (various replacement parts put at hand). The trolley
shall be parked on one end of the girder (i.e., the end where the gantry wheels are
not to be replaced). The gantry leg shall be lifted by two 32t jacks which shall be
placed under the bearing pedestal of the other wheel that is not to be replaced and
fitted under the same equalizer beam with the wheel to be replaced (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.
8.3. 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 their condition carefully observed. Then operation with a load
can be started.
8.4. Inspection items and period for maintenance
8.4.1. Oil (grease) supply
During oil (grease) replacement the old oil (grease) shall be discharged
thoroughly. Generally speaking, the lubricant, especially the grease shall not be
mixed. Mixed grease may result in blockage and bearing damage.
8.4.2. All parts and components
8.4.2.1. Loosening of securing bolts
Attention shall frequently be paid to loosening of the bolts, particularly after the first
week of Crane running, and then once per month check all the bolts and re-tighten
them.
Special attention shall be paid to those bolts that contribute to fastening but are
easily neglected.
Period: routine and once per month
8.4.2.2. Check whether lubrication is correct.
Lubricate in accordance with lubrication schedule.
Period: routine
8.4.3. Motors
8.4.3.1. Check temperature rise for any abnormal condition
8.4.3.2. Check for any abnormal heating in the bearings.
8.4.3.3. Check for any abnormal noise in the motor.
8.4.3.4. Axial play of the motor is generally controlled within 3mm and the maximum
shall not exceed 5mm.
Period: routine

User’s Manual and Maintenance Manual Page 16 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

8.4.4. reducer
8.4.4.1. Check whether oil level is adequate by using the oil level detector.
8.4.4.2. Check for oil leakage.
8.4.4.3. Check for abnormal temperature rise. If the casing temperature is higher
than the ambient temperature by more than 40qC, the inner part shall be inspected.
8.4.4.4. Check for abnormal noise in the internal part and disassemble and inspect
if there is any.
8.4.4.5. Check for loosening of connection bolts.
Period: all above are routine.
8.4.5. Wheels
8.4.5.1. Check whether wear of wheels exceeds permitted limit.
8.4.5.2. Check that every tyre is inflated sufficiently.
Period: routine

9. Sway-damping device
9.1. Composition of sway-damping device and its function
The RTG is provided with eight (8) hoist wire rope reeving system without
additional device to sway–damping for improving sway-damping result.
The eight(8) hoist wire rope reeving system is an effective system. Sway of the
container with rated load can be controlled within r50mm in 2.5 cycles under the
condition that the trolley and gantry runs at the full speed when the spreader
bottom is 4m above ground.

9.2. Points for Attention in Operation

After a long period of non-operation or after disassembly and re-assembly the
crane shall be first run with no load allowing the bearings, etc. to be lubricated
fully, then operation with load can be started.

9.3. Inspection Items and Period for Maintenance

9.3.1. Oil (grease) supply
During oil (grease) replacement the old oil (grease) shall be discharged
thoroughly. Grease shall not be mixed because mixed grease may result in
bearing damage.
9.3.2. All parts and components
9.3.2.1. Check bolts for loosening
Frequently check bolts for loosening, particularly after the first week of running and
then once per month check all the bolts and re-tighten them. Pay special attention
to those securing bolts that may easily be neglected.
Period: routine and once per month
9.3.2.2. Check that lubrication is correct
Lubrication shall be done in accordance with the lubrication schedule.

User’s Manual and Maintenance Manual Page 17 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

Period: routine
9.3.3. Sheaves
9.3.3.1. Check whether the sheave bearing is overheated. It is necessary to inspect
the inner part if the temperature of the casing is higher than the ambient temperature by
40qC.
9.3.3.2. Check whether bolts on the hollow cover are loosened and if the rope
groove is worn.
Period: routine
9.3.4. Limit switches
9.3.4.1. Check whether the securing nuts of the limit switches are loosened.
9.3.4.2. Check whether their position has shifted.
Period: routine

10. The Power Unit

10.1. Composition of the Power Unit
The power unit of the Crane consists of the diesel engine, Model TAD1642GE by
VOLVO, and an alternator HCI 634J2 by STAMFORD. Horsepower of the diesel
engine is 684HP, and the alternator has power of 850KVA. The diesel engine -
alternator set supplies power to every movement mechanism through a silicon
controlled rectifier. The whole power unit has a common base frame so that the
set may be replaced and repaired. The engine starting, accelerating, stopping may
be controlled either in the engine room or from the operator’s cab.

The engine is provided with protection from overheating by cooling water, low
pressure of lubrication oil, overspeed and frequent starting, etc. When the water
temperature is too high or lubrication oil pressure is too low, the fuel throttle
(accelerator) is shut off and acoustic and visual alarms will be sent to the
operator’s cab.
10.2. Points for Attention in Operation
10.2.1. Light diesel oil shall be used for the engine normal starting.
10.2.2. In winter, if the temperature is low than 0 degrees Celsius, antifreeze should
be added to the cooling water to prevent freezing and damage to the engine.
10.3. Inspection Items and Period for Maintenance
10.3.1. Make a record of water temperature, oil pressure, etc. daily.
10.3.2. The air filter is provided with block indicator and the red color display in the
indicator shows that the strainer is blocked by dust and should be replaced.
10.3.3. The lubrication oil filter normally serves for 300 hours and then the filter
element is replaced.
10.3.4. The fuel filter serves 300 hours and the filter element is then replaced.
10.3.5. Maintenance of the engine and alternator shall be done in accordance with
the Instructions for the diesel engine and the alternator.

User’s Manual and Maintenance Manual Page 18 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

11. Energy Chain System

11.1. Construction and Performance

Control power of the main hoist, trolley traversing, spreader slewing and the power
for the spreader is supplied through able energy chain system suspended cable that
connects the operator’s cab and the electrical room. Following the trolley traversing,
the cable chain traverse to extend or retract the cable. One end of the cable chain is
fixed to the girder, and the other end is fixed to the trolley, and the cable is led into
the junction box on the operator’s cab.

Points for Attention for Maintenance

Frequently check bolt connections and fastening by bolts and re-tighten bolts if
they are loosened.
For details, refer to the Instructions for the energy chain.

12. Spreader and Headblock

12.1. General
The Crane is provided with full electric drive telescopic spreader with headblock on
which the adjusting cylinders cable basket, and power junction box, etc. are
installed.
The spreader is a BROMMA product, that is able to handle 20c, 40c, 45c and twin
20c standard containers.
To change the spreader quickly, the spreader is attached to the headblock through
four standard twistlocks. Easily engaged electrical connectors are used for
connection to the spreader.

12.2. Points for Attention for Maintenance

Maintenance of the spreader should be done with special care since it undertakes
the essential lifting and lowering of heavy containers. The spreader shall be
operated correctly and maintained properly to ensure its service life and to avoid
accidents.
12.3. For details, refer to the Instructions for the Spreader.

12.4. Inspection Items before Operation:

12.4.1. Check that the wire rope is in normal condition;
12.4.2. Check for abnormal conditions on the base frame and other parts;
12.4.3. Is there any tool or object left on the spreader?
12.4.4. Any loosening of nuts, bolts?
12.4.5. Is the action and position of twistlocks correct?
12.4.6. Is the position of twistlocks correct at the container?
12.4.7. Is the load to be lifted in excess of permitted limit?
12.4.8. Is the centre of gravity of the load to be lifted within permitted range?

User’s Manual and Maintenance Manual Page 19 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

12.5. In case of accident

In case of any abnormal noise or accident, the spreader shall be removed from the
headblock and inspected and repaired.
12.6. Periodic Maintenance
The spreader shall be carefully maintained since it directly lifts the load.
12.6.1. Inspection before operation
Refer to Points for Attention in Operation.
12.6.2. Inspection per month
12.6.2.1. Visual inspection
12.6.3. Examine the base frame, spreader beam joints, brackets, flippers, etc. for
cracks.
12.6.4. Any paint peeling off?
12.6.4.1. Any trouble in the twistlock device?
12.6.4.2. Any loosening of nuts, bolts? Tighten if necessary.
12.6.4.3. Is insulation of electrical parts correct?
12.6.4.4. Is there loosening of the screws for connection of the wires into junction
box?
12.6.4.5. Inspection per year
In addition to the above-mentioned items per month, the following shall be
inspected yearly:
12.6.4.5.1. The strength inspection, and the major location may be inspected through
dyeing (including the base frame, spreader beam joints etc.)
12.6.4.5.2. The twistlock pins dimensions.

User’s Manual and Maintenance Manual Page 20 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

13. Crane Inspection, Maintenance and Repair

13.1. Crane Travel Operation:
13.1.1. In non-operational conditions the trolley shall be anchored.
13.1.2. The Crane traveling is controlled with operation switch and limit switch
interlocks; therefore, the control parts such as limit switches shall not be removed without
permission.
13.2. Management
13.2.1. The Crane shall be operated in accordance with ĀOperation Manual for the
Electrical System” since the electrical devices are controlled through the PLC and
Siemens system.
13.2.2. Before operation the activation of limit switches for every mechanism shall
be confirmed to be accurate.
13.2.3. Pay close attention to the fastening bolts of 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 and lowering.
13.2.4. Pay attention to the brake disc and brake shoe pads that 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 1.0 mm.
13.2.5. Frequently check that the remaining wraps of the main hoist wire rope on
the drum are more than (3) three. Check whether the rope clamp bolts on the drum are
loosened and re-tighten them if necessary. Bolt loosening may result in the wire rope
falling.
13.2.6. Malfunction of the limit switches due to wire rope stretch should be
corrected through adjustment of the rope length. Particularly after rope replacement the
new wire rope may be stretched after a certain time period of operation and, therefore,
for the first stage of operation of new wire rope more frequent inspection should be
made.
13.2.7. The wire rope lubrication shall be checked every day and lubricant added if
necessary.
13.2.8. Replace parts when they are worn to the permitted limit.
13.2.9. Carefully check the wire rope end securing bolts, especially the following
bolts and re-tighten them:
13.2.9.1. Securing bolts on wire rope clamps on the drum;
13.2.9.2. During wire rope replacement care must be taken not to damage the thread
on the bolts for the rope clamp because with damaged thread the bolts cannot be
tightened to adequate torque. Also take care not to damage the threads on other bolts of
the mechanical devices.
13.2.10. After installation has been completed or after re-tightening, loosening of
some bolts in mechanical parts may result in misalignment, vibration, heating, etc. That
may cause reduction of service life of the corresponding components or may be the
cause of running failure.
13.2.11. Routinely re-tighten bolts, nuts, etc.

User’s Manual and Maintenance Manual Page 21 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

Re-tightening operation of bolts and nuts:

After 7 After 14 After 1 After 3 After 6 After 1

days days month months months year
Motor securing bolts 0 0 0
Brake securing bolts 0 0 0
Brake disc nuts 0 0 0
Reducer securing bolts 0 0 0
Shaft system
0 0 0
Securing bolts
Mechanical base frame
0 0 0 0
Securing bolts
Wire rope securing
0 0 0 0
Bolts on the drum
Wire rope clamp bolts 0 0
Connectors in the
0 0 0
Control cabinet
Connectors of the
0 0 0
Resistor grids
Connectors in the
0 0 0
Operation box
Connectors of
0 0 0
Limit switches

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

13.3. Maintenance and Inspection

Maintenance of the crane is done to ensure good crane performance and to
prevent accidents.
Maintenance includes routine maintenance and regular inspection. In addition, in
case of typhoons or earthquakes it is necessary to inspect and confirm
precautions taken and to inspect after these events.

User’s Manual and Maintenance Manual Page 22 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

13.3.1. Points for Attention for Maintenance, Inspection and Repair

13.3.1.1. 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.
13.3.1.2. During maintenance, inspection or repairing the following matters must be
observed in addition to contacting related authorities:
13.3.1.2.1. If there is a Crane nearby, the ant -collision device must be carefully
inspected to prevent collision.
13.3.1.2.2. During maintenance, inspection or repairing, a sign “under Repair” shall be
posted at a conspicuous place under the Crane to protect personnel from injury.
13.3.1.2.3. 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.
13.3.2. Record of Maintenance and Inspection Results
The following maintenance and inspection records are attached to these
Instructions. The results are necessary for the Crane repairing and modification
and shall be carefully recorded.
13.3.2.1. Routine Inspection Items
13.3.2.1.1. Confirming performance and ambient safety before operation.
13.3.2.1.2. Observe the Crane’s condition and stop operation after any abnormal
condition is found.
13.3.2.1.3. After operation has been completed, the Crane shall be stopped at the
correct position and it should be confirmed that there is no abnormal condition.

13.3.2.1.4. Before starting operation

Inspection
Inspection Items
Method
1. Obstruction within traveling range and the load traveling path Visual
2. Obstruction on trolley rail track Visual
3. Wire rope jumping off the drum or sheave or contact of the rope Visual
with any obstruction
4. Lack of lubrication in wire rope, strand breakage, loosening of Visual
clamp bolts
5. Inspection of brake pads Visual
6. Remedied condition of the defects found on previous day Activation
7. Inspection of brakes Starting
8. Various instrument panels and indicator lamps Starting
9. Activation of various operation joysticks and button switches Starting
10. Activation of major limit switches (main hoist, trolley, spreader) Starting

13.3.2.1.5. During operation

Inspection Items Inspection Method

1. Abnormal sound, heating, vibration Visual
2. Abnormal current, voltage Visual
3. Activation of the spreader Visual

User’s Manual and Maintenance Manual Page 23 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

13.3.2.1.6. After Operation

Inspection
Inspection Items
Method
1. Inspection of spreader Visual
— Deformation and fracture of base frame Visual
— Deformation and fracture of twistlock pins and flippers Visual
— Damage and torsion on spreader cable Visual
— Loosening of securing bolts Visual
2. If the various joysticks return to off position Visual
3. Any oil leakage at various oil pumps and hoses Visual
4. If various bearings, gears and other lubricated parts are normal Activation
5. Any abnormal heating Visual
6. Any fracture or damage on various components Visual
7. If the power switch is disconnected Starting
8. If power pack is switched off Visual
9. If various components are clean Visual
10. If the operator’s cab door is locked Visual
11. Operation log and record of container handling for shift transferring

13.3.2.2. Items Inspected per week

The objective of this inspection is to find out defects between monthly inspections.

Inspection Time Inspection Items Inspection Method

1. Any loosening of bolts and
Visual
damage of bearings
2. Any loosening of various pins,
Visual
key boards and end stopper boards
After operation 3. Any torsion, damage, cracks of
festoon cable and any loosening, Visual
corrosion of terminals
4. Activation of electro - magnetic
Activation
contacts, knife switch, etc.

13.3.2.3. Items Inspected every month, every year

The objective of regular inspection is to inspect the major parts of the Crane in
detail and to propose disassembly and repair when necessary and to find out
troubles that are not found during routine and weekly inspection and propose
repairing. Regular inspection is divided into monthly and annual inspection.

User’s Manual and Maintenance Manual Page 24 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

Items inspected every month/year

Monthly Inspection Annual Inspection
Category
Inspection Items Inspection Items
1. Loosening of securing bolts 1. Corrosion of steel
2. Fracture of welds 2. Peeling off of coating
Steel 3. Deformation, fracture of steel 3. Wear of shafts, pins
structure 4. Grease for shafts, pins
5. Loosening of bolts on stairs,
handrails, platforms
Steel structure

1.Fracture of welds 1. Rail span

2. Elevation difference between
2. Rail end wear and sinking
the two rails
3. Bending in vertical direction
4. Bending in horizontal
Trolley rail direction
5.Slope
6. Misalignment of rail joints
7. Damage and corrosion of
end bumpers
8. Damage and corrosion of rail
1. Abnormal noise, abnormal
1. Cracks of casing
heating, abnormal vibration
2. Condition of teeth washing 2. Loosening of the key
Gearing
3. Lubrication 3. Deformation of the key slot
4. Oil level, oil leakage 4. Contamination of oil
5. Loosening of securing bolts
1. Abnormal noise, abnormal heating 1. Any cutting scrap in the oil
(grease)
Bearings 2. Damage or fracture of the body 2. Clearance between the pin
and bush
3. Loosening of securing bolts 3. Wear of the bearing
Mechanical

1. Wear, fracture
Shaft 2. Loosening of the key
3. Deformation of the key way
Key 1. Deformation
1. Loosening of bolts(once /year)
Operator's
bolt
1. Abnormal noise, heating 1. Alignment
2. Oil amount (grease) 2. Supply of oil (grease)
Gear 3. Oil leakage 3. Teeth backlash
coupling 4. Loosening of securing bolts 4. Loosening of the key
5. Deformation of the key way
6. Damage of fracture of teeth
Wheel 1. Wear, deformation of the tread
surface
User’s Manual and Maintenance Manual Page 25 of 41
 PORT SAID, EGYPT 9 RTG PROJECT

Monthly Inspection Annual Inspection

Category
Inspection Items Inspection Items
2. Deformation of the key, bolts
loosening
1.Loosening of wire rope fixing 1. Wear on the rope groove
2.Damage to the wire rope guide
Drum
3.Damage to drum securing bolts
4.Fracture of welds
1.Revolving condition
2.Fracture
Sheaves 3.Rope groove wear
4. Damage to wire rope anti-slipping
device
1.Broken wires in strand
2.Wear and external damage
3.Bending, deformation
Wire rope 4.Strand loosening
5.Greased condition
6.Rust and corrosion
7.Fixing condition of wire rope end
1. Deformation and fracture of the 1. Wear of the pins, shafts etc.
base frame
Mechanical

2. Damage, deformation and wear of

twistlock pins, flippers, etc. 2. Peeling-off of coating
Spreader
3. Loosening of securing bolts 3. Corrosion of steel
4. Center to center of twistlocks
5. Activation
1. Contamination of grease and
ageing, discolor of grease
Grease 2. Grease supply at lubrication
supply points
3. Damage and oil (grease) leakage
in piping
1. Oil level and oil contamination
2. Filter cleanliness
3. Oil pressure
4. Abnormal noise, abnormal heating
Hydraulic of oil pump, oil motor
unit 5. Adjustment and action of values
6. Action of oil cylinders
7. Damage to oil piping
8. Oil leakage anywhere
9. Loosening of securing bolts

User’s Manual and Maintenance Manual Page 26 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

13.3.2.4. Inspection Items after a storm

After a storm or earthquake the Crane shall be inspected.
Inspection Items:
13.3.2.4.1. Any obstruction within the Crane’s traveling range?
13.3.2.4.2. Is stowage device in normal condition?
13.3.2.4.3. Were the traveling motors and brakes immersed in water?
13.3.2.4.4. Were the stairs, walkways and hand railings damaged?
13.3.2.4.5. Any deformation or fracture of welds on structural members?
13.3.2.4.6. Did wire ropes jump from grooves of sheaves and guiding rollers?
13.3.2.4.7. Any damage to wire ropes?
13.3.2.4.8. Any interruption of oil (grease) supply system ?
13.3.2.4.9. Any damage, rainwater in operator’s cab, engine room and electrical room?
13.3.2.4.10. Is diesel-alternator set normal?
13.3.2.4.11. Is insulation resistance value reduced?
13.3.2.4.12. Any damage to lighting fixtures?
Points for Attention after Inspection
13.3.2.4.13. Add oil (grease) to all oil (grease) supply points
13.3.2.4.14. Run each movement with no load.
13.3.2.4.15. Confirm activation of every limit switch.
13.3.2.4.16. When it is confirmed that there is not any trouble or obstruction in operation,
the Crane may be put into normal operation.

13.4. Preparation of the Crane

13.4.1. When starting operation the Crane shall be run first without load and the
action of brakes, bolts, etc. shall be inspected.
13.4.2. Frequently check the operation joysticks and keep them clean. Frequently
grease each sliding part.
13.4.3. For motors, electro-magnetic brakes, resistors, thrusters, operation
joysticks etc, refer to operation Instructions for Electrical Parts.

User’s Manual and Maintenance Manual Page 27 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

13.5. Lubrication of the Crane

13.5.1. General
13.5.1.1. Frequently replenish oil in the gear reducer to keep the oil level within
specified range. When the oil is contaminated, it should be replaced.
13.5.1.2. At least more than once per month grease all the lubrication nipples until all
the old grease is pressed out.
13.5.1.3. Properly grease connection pins. For moving auxiliary devices without
grease nipples, drip oil with oilcan.
13.5.1.4. Brake pads and electrical connectors shall not be greased (oiled).
13.5.2. Points for Attention for Lubrication
13.5.2.1. Lubrication materials must be kept clean.
13.5.2.2. Lubrication greases of different brands shall not be mixed.
13.5.2.3. Frequently check sealing of lubrication system.
13.5.2.4. Select appropriate lubrication materials and lubricate according to the
specified schedule.
13.5.2.5. Lubrication shall be carried out when Crane power is off.
13.5.2.6. For revolving parts without grease fittings, the oilcan should be used to drip
oil into the clearance for reducing wear and prevention of rusting.
13.5.2.7. Periodically check quality of oil where components and parts are lubricated
through oil bath.
13.5.2.8. For grease-lubricated points, the old grease shall be discharged as much
as possible and then the fresh grease may be added.

User’s Manual and Maintenance Manual Page 28 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

13.5.3. Crane lubrication schedule

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
Lubrication
No Description Lubrication type Lubrication material
period
NO 2 Lithium-based
lubricant,
Normally 15-30 Lay on the surface of Compound calcium
1 All wire ropes
days rope - based graphite
lubricant or other
grease
2 Main hoist reducer First time Oil bath
Self-
3 Trolley reducer half-year. Oil bath
lubricat L-CKC 320 gear oil
Gantry traveling Then, one
4 ed Oil bath
reducer year
High speed end:
Operation
Rolling bearing once per month Lithium-based
5 temperature
and gear coupling Low speed end: lubricant
-20q-50qC
Two months
High speed end: Operation
once per day Industrial lithium-
temperature higher
Low speed end based lubricant
than 50qC
6 Plain bearing once per week
Add grease fully Operation
at each time of Use No. 1, 2 special
temperature lower
overhauling grease
than -20qC
Compound
General motor aluminum-based
Electrical Annual repair or
7 insulation or grease, No.3
Motors overhaul
tropicalized lithium-based
grease
All point points of
HC 20 mechanical
8 brakes, limit Two months Pins
oil
switches, joysticks

Main hoist
command limit,
Open gearing, Lithium--based
9 Two months
Hinged pin of grease
universal coupling
of the trolley,

All sheaves’
shafts and Lithium--based
10 One/two months Auto- Lubrication
trolley’s wheel grease
bearing

User’s Manual and Maintenance Manual Page 29 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

13.6. Common Troubles and Troubleshooting for the Crane

13.6.1. Classification of the Crane Troubles
The Crane is used for lifting and handling goods. It is used widely in modern
industry, transportation and capital construction. However, after a certain period of
operation some troubles may appear due to wear and increase of clearances or
fatigue of some major members 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.
13.6.1.1. Trouble in mechanical part
Any assembly consists of a number of parts and components and these
assemblies form the mechanism of the Crane. Mechanical trouble with the RTG
occurs mainly in the diesel engine alternator set, motors, brakes, reducers, sheave
blocks, drum, spreader, couplings, traveling wheels, etc. Surface wear occurs
during their movement, and when the wear reaches a certain value the Crane’s
operation may be affected.

Brakes are one of the essential components on the Crane and their performance
governs the accuracy of each movement and safety of operation. 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. Troubles with
the brakes are mainly due to poor action of the transmission system, jamming of
the pivot pins, worn out parts or the clearance between the brake pads and brake
disc is improperly adjusted. Sometimes failure of the brakes results from trouble
with the thruster or the brake size is inadequate with too small a braking torque.

In a Crane, the reducers are used for main hoist, trolley traversing and gantry
traveling to transfer the mechanical torque and to reduce revolutions. The
performance of reducers directly affects the Crane’s safe operation. After a long
period of running, the teeth surfaces may suffer fatigue, pitting and wear that result
in abnormal noise, vibration and heating. Therefore, if any defects are found in the
reducer, they must be eliminated immediately.

The couplings are also used for torque transfer but the speed is unreduced.
Couplings are divided into rigid couplings and flexible couplings. Wear of the teeth
commonly results from poor installation with misalignment between the two shafts
coupled and poor lubrication. Serious wear of the teeth on the gear coupling may
cause failure of transmission and/or serious accident.

The most common trouble with the sheave and drum is wear of the rope grooves.
The reason is that during no-load running the wire ropes in the grooves are
slackened and when operation with load is started the wire ropes are tensioned
and press the rope grooves with a certain pressure. Therefore, during hoisting or
lowering, slip between the wire rope and the groove of sheave and drum occurs. In
addition, since the wire rope has a sharp angle to the rope groove the rope groove

User’s Manual and Maintenance Manual Page 30 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

is seriously worn at its tip. The sheave and / or drum shall not be used any longer
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 the rope and finally result in breakage of
the rope.

13.6.1.2. Trouble in the steel structure

The quality of the Crane structure directly affects Crane safety. Once the structure
is damaged, a serious accident may occur. Therefore, the Crane steel structure is
designed to meet the strength, rigidity and stability requirements.

If cracks appear in the welds, the Crane may not be operated normally and safe
production may be affected.

13.6.1.3. Trouble in the Electrical Part

Motors are required to have great mechanical strength and high overload
capability. They are subject to frequent mechanical vibration and shock and they
shall have small moment of inertia to be started and broken rapidly. There should
not be any noise due to friction, any shrill sound or other noise during motor
running, and they should be stopped for repairs if these noises appear. Water and
oil shall not be dripped into the motor during operation. The troubles with the motor
mainly are disabling of starting, high temperature rise and that the power cannot
reach rated value during running with load.

Electrical equipment is a more complicated part of the Crane, and it is easily

affected by shock and vibration, especially in an ambiance of high temperature,
dust, and high humidity. Failure of the electrical equipment results not only in
stopping of production but also accidents.
Electrical equipment on a Crane includes motors, electrical magnet, controls,
resistors and other components such as conductors, slip ring devices and various
control circuits. For details refer to the “Electrical Operation Manual”.
13.6.1.4. Trouble in the Hydraulic System
Troubles in the hydraulic system that commonly happen during operation are
divided into new problems and those due to wear. The former are due to damage
to the pump, parts and breakage of piping, etc., which are dependent on the
quality of fabrication, installation and compliance with the approved operation
procedure. These troubles often occur in the first and intermediate stage of
service. The troubles due to wear include sealing failure, operating speed slowed
down, etc. Often these occur at the last stage of service and are the result of
normal wear, and these troubles are affected by routine maintenance. Therefore,
to increase the service life of the hydraulic system and ensure good performance,
compliance with operation procedure and the established routine maintenance

User’s Manual and Maintenance Manual Page 31 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

system must be observed. For detailed instructions, refer to the “Hydraulic

Operation Manual”.
13.6.2. Causes of Common Troubles and Troubleshooting
13.6.2.1. Causes of general troubles in the Crane parts and components and their
remedies are shown in the following table:

Troubles Causes Remedy method

Lack of grease or no grease Add sufficient grease
High temperature
Clean the bearing with
in rolling Contamination in the
kerosene and fill with
bearing(s) bearing(s)
grease
Poor installation
misalignment of the bearing Check correctness of
Noise in rolling or over tightened and installation and adjust
bearing is increased jammed
Damaged or worn bearing
Replace bearing
elements
Periodic chattering
noise of the gearing Excessive error of the teeth
in the reducer, pitch. Teeth lateral backlash Remedy, re-assemble
particularly from the exceeds standard value
idle gear wheel
Clearance of gearing is too
Sharp friction sound small, misalignment of the
Remedy, re-assemble or
and clatter sound in gear wheel, sharp and thin
replace
the reducer edge on the teeth top, teeth
face uneven due to wear
Uneven meshing,
continuous knocking
sound heard from
Defects on tooth lateral
any point on the Replace
surface (laminated texture)
reducer casing and
vibration of the
reducer
Excessive axial backlash of
Knocking sound in Replace
the worm or the teeth of
the worm gear
worm gear are seriously
reducer, alternate
worn, pitch circle of the
high and low and the
gear is eccentric in relation
period coincides with
to the shaft, accumulated
that of gearing
error of the circular pitch of
rotation sound Repair or re-assemble
the gear
Oil temperature <60qC
for cylindrical and bevel
gear reducer, and <70qC
Heating of the
Lack of oil for worm gear reducer.
reducer
Oil level shall be kept
between the two pointer
scales

User’s Manual and Maintenance Manual Page 32 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

Troubles Causes Remedy method

Excessive wear of gear
Replace gear wheel
wheel
High noise of shock
Remove the foreign
in the gear reducer Foreign matter in the casing
matter
Bearing is damaged Replace bearing
Disassemble and clean
Contamination in bearing
Bearing overheated the bearing
in the reducer Too small clearance Adjust
Lack of grease (oil) Add grease (oil)
Clean up the brake
Jammed pivot linkage in
element jam and grease
lever system
the pivots
Clean brake disc and
Oil (grease) on the brake
brake pads with
Brake(s) can not hold disc or brake pads
kerosene
the load (excessive
Excessive wear of the
braking distance of Replace brake pads
brake pads
the trolley or gantry)
Main spring damaged or Replace spring or adjust
loosened results in the nut to make the
insufficient tension spring tension sufficient
Loosening of the lock nut of Adjust the lever and
the lever, lever’s play tighten nut
Uneven clearance between
brake disc and brake pads,
Burnt spots on brake Adjust clearance to make
friction appears when
disc and rapid wear it even, replace auxiliary
released and the disc is
of brake disc spring
heated, auxiliary spring is
damaged or bent
Adjustment nut is not
Brake is easily Adjust brake tighten nut
tightened or lock nut is not
deviated from the and lock nut, or replace
tightened, thread of the nut
adjusted position defective nut
is damaged
Rapid wear or
Contamination and lack of Clean and lubricate the
frequent breakage of
grease wire rope
wire rope
Disassemble and
Sheave does not Lack of lubrication between lubricate parts and add
rotate shaft and bush grease
Too high resistant force at
Clean up every pivot
various pivot points of
point and grease
brake(s)
Too low oil pressure or oil Clean piping and fill in
Too long starting piping blocked with oil as necessary
time of brake(s) Clean and check
hydraulic thruster for
Internal oil leakage noise; damaged parts
shall be replaced
immediately

User’s Manual and Maintenance Manual Page 33 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

Troubles Causes Remedy method

Orifice of pressure relief Clean pressure relief
value is blocked value
The solenoid is reversely
No pressure in connected and the thruster
Adjust wiring
hydraulic thruster, no can not be pushed
braking downward
Tighten the fitting of the
Pump fitting is not tightened
pump
Filter is blocked Clean the filter
The plane of the control
Pressure in hydraulic lever of the adjustable
thruster can not device of pressure relief is Find out the failure point
reach operating not leveled; control lever and correct it
pressure value has deviated from the
center of nozzle
Insufficient current in the
Too long braking Increase current within
solenoid of electro-hydraulic
time permitted range
adjustment device

Slightly tighten the upper

Release time by the Small distance between the
end nut of the cross-
hydraulic thruster is control lever and the nozzle
spring
too long, residual
pressure too high
Too small diameter of the Enlarge the bore
nozzle bore diameter
Too high tension of the Adjust the tension of the
The brake can not be main spring spring
released Repair or replace
Thruster is damaged
hydraulic thruster

User’s Manual and Maintenance Manual Page 34 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

13.6.2.2. Regular Inspection Items (Mechanical) for the Crane

Inspected
Inspection Items Inspection
Components Inspection
method and Inspection criteria
Descrip No. period
No. apparatus
tion Description
Visual, with Indicated range on
1 Lubrication oil amount Per month
oil scale the scale
Fixed joint: no
leakage.
2 Sealing Visual Per month
Relatively moving
joint: no drip
Testing,
No abnormal sound,
3 Running condition hear and Per month
abnormal heating
feel
1. Reducer Knock and
4 Bolt connection No loosening Per month
test
Chemical To specified by Every
5 Oil quality
analysis standard season
Tooth face smooth
Every
6 Gear meshing Visual test and clean normal
season
meshing
Wear is less than
7 Wear of gear wheel Measure 10% tooth original Every year
thickness
Wear is less than
Wear of the drum Every half
1 Measure 15%original
shell a year
thickness
2. Drum 2 Wire rope clamp Knocking No damages Per month
3 Rope grooves Visual No damages
4 Fatigue cracks Visual No damages Per month
5 Bearing lubrication Visual Proper lubrication Per month
Grease is not dried,
1 Lubrication Visual Per month
distributed uniformly
Diameter reduced
2 Wear Measure by Per month
<7%
3. Wire rope
Broken wire
Wire broken, strand
3 Visual <10% no strand is Per month
broken
broken
No torsion, no
4 Torsion or corrosion Visual Per month
corrosion
4. Sheave 1 Cracks Visual No cracks Per month
User’s Manual and Maintenance Manual Page 35 of 41
 PORT SAID, EGYPT 9 RTG PROJECT

Inspected
Inspection Items Inspection
Components Inspection
method and Inspection criteria
Descrip No. period
No. apparatus
tion Description
Maneuverable, no
2 Sheave rotation Hearing test Per month
abnormal noise
Uneven wear of the Every
3 Measure Less than 3mm
groove season
Wear of groove 20% original Every
4 Measure
thickness thickness season
Wear at groove <50% wire rope Every
5 Measure
bottom diameter diameter season
6 Damage Visual No damage Per month
Hearing, No abnormal noise
7 Bearing Per month
visual proper lubrication
1 Brake base frame Visual No cracks Per month
Wear of thickness of <50% original
2 Measure Per month
brake pads thickness
Visual, No yield Every
3 Spring
measure deformation season
<5% original
4 Wear of shaft or bore Measure Per month
diameter
No oil drip, normal
Hydraulic/Electric
5 Visual activation/no nuts Per month
thruster
5. Brake loosening
Clearance when Visual >0.6mm,
6 Per month
released measure <1.5mm
Knocking
7 Bolts, nuts test hammer No loosening Per month
test
Normal operation,
Testing and reliable, no
8 Operation condition Per month
observe abnormal heating,
smell, and action
1 Brake disc body Visual No cracks Per month
Wear in disc <4% original Every
2 Measure
thickness thickness season
6. Brake disc
Unevenness of disc Every
3 Measure <1.5mm
surface season
4 Friction surface Visual No cracks Per month
1 Coupling body Visual No cracks Per month
7. Coupling No damage, normal
2 Pins Visual Per month
wear

User’s Manual and Maintenance Manual Page 36 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

Inspected
Inspection Items Inspection
Components Inspection
method and Inspection criteria
Descrip No. period
No. apparatus
tion Description
Wire rope end, screw No abnormal
1 Visual Per month
lever condition, no cracks
8. Wire rope Visual, Normal, no Per month
2 Bolt connection knocking loosening
suspension
test
device Normal operation,
Wire rope support
3 Visual no deformation at Per month
rollers
deport, no cracks
To meet
1 Grease amount Visual Per month
requirement
9. Lubrication 2 Quality of grease (oil) Visual To meet regulation Per month
points. No damage, Every
3 Nipples and tubing Visual
unblocked season
1 Wheel body Visual No cracks Per month
Wear of wheel flange Measure <50% original Every
10. Trolley 2 thickness thickness season
Wear of tread in Measure <15% original Every
wheels
3 thickness thickness season
Every
Ellipticity Measure <1mm
4 season
1 Inflation pressure Measure 10.0kg/cm2 Per week
2 Surface of the tyres Visual No cracks Per week
3 Visual, Proper lubrication,
11. Rubber Wheel bearing Per week
testing no abnormal
tyres
Visual,
Normal condition,
4 Connection bolts knocking Per week
no loosening
test

1 Air fitter Visual Clean Per week

Foreign matter and

2 Lubrication oil Check water content meets Per month
standard
12. Diesel No missing, no
Water tank cover Visual Per week
engine 3 damage
No missing, no
4 Diesel fuel tank cover Visual Per week
damage
Tension meets
5 Fan belt Test Per month
requirement
6 Sealing Visual No leakage Per week
7 Abnormal noise Hearing No abnormal noise Per week

User’s Manual and Maintenance Manual Page 37 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

Inspected
Inspection Items Inspection
Components Inspection
method and Inspection criteria
Descrip No. period
No. apparatus
tion Description
Carbon brushes & Test run, No sparks during
Per week
1 commutator visual running
Wear of carbon Thickness Per
Measure
2 brushes >20mm season
Pressure of brush Per
Measure 1.8-2.0N/cm2
3 spring season
Resistance of >1M: in cold state Per
Measure
4 insulation >0.5M: in hot state season
13. Alternator Visual,
No damage, no
set 5 Wire connection knocking Per week
loosening
test
Filtered cover of the No dust & foreign
6 Visual Per week
ventilator matter
No defects, tension
7 Transmission bolt Testing Per month
meets specified
No abnormal noise
Running condition Test run Per week
no abnormal heat
No defects such as
1 Horizontal wheel body Visual Per month
cracks
Clearance between
Measure 3--4mm Per month
2 the guiding rail
14. Trolley Visual, No abnormal
horizontal Bolt connection knocking condition, no Per month
3
wheel test loosening

Lubrication Lubricate Proper lubrication Per month

4
Meet technical Per
Wear Measure
5 requirement season
No cracks, no teeth
Gear wheels Visual Per month
1 breakage
<30% meshing face,
Pitting on teeth face Visual depth <10% original Per month
15. Gearing 2
tooth thickness
Wear of tooth
3 Measure GB6067-85 Per year
thickness
4 Lubrication Visual Proper lubrication Per month
16. Visual, No loosening
1 Connection Per week
Universal knocking correct
2 Lubrication Lubrication Proper lubrication Per week

User’s Manual and Maintenance Manual Page 38 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

Inspected
Inspection Items Inspection
Components Inspection
method and Inspection criteria
Descrip No. period
No. apparatus
tion Description
transmission 3 Parts of shaft Visual No cracks Per week
Visual No abnormal
17. Chain 1 Running condition Per week
inspection condition
sprocket
and chain 2 Damage Visual No damage Per week
3 Lubrication Visual Proper lubrication Per week
No damage &
1 Bumper body Visual Per month
cracks
Visual No cracks, firm
18. Bumpers 2 Support Per month
knocking connection
No abnormal
3 Spring Visual Per month
condition
No cracks, no
1 Cracks, damage Visual, NDT Per year
19. Headblock damage
twislock As technically Per
2 Wear Inspection
required season
Visual,
1 Load bearing No damage no wear Per month
Measure
20. Spreader
No defects, wear
telescopic Visual,
2 Rail within permitted Per month
Measure
range
Visual, Perfect no
1 Cable clamp Per month
knocking loosening
21. Energy 2 Chain Visual No damage Per month
Chains Visual,
3 Bolt connection No loosening Per month
knocking
4 Cable Visual No damage Per month
No plastic
1 Plastic deformation Visual Per month
deformation
2 Damage Visual No damage Per month

Turning angle Testing 00, 900 Per month

3
22. Spreader As technically
Wear Measure Per year
twistlock 4 required
23. 5 Cracks Visual NDT No cracks Per year
No cracks,
Visual, ultrasonic and X-ray
telescope test if necessary,
rulers depth of corrosion
<10% weld height
User’s Manual and Maintenance Manual Page 39 of 41
 PORT SAID, EGYPT 9 RTG PROJECT

Inspected
Inspection Items Inspection
Components Inspection
method and Inspection criteria
Descrip No. period
No. apparatus
tion Description
Steel Box- Painting Visual, No large area of per
structure section telescope peeling off season
members
1 Welds Visual, No cracks,
telescope ultrasonic and X-ray
rulers test if necessary
depth of corrosion
<10% weld height
Plate Visual, No cracks, local
surface rulers deformation
<3%depth of
corrosion
<10%
2 Walkways Oil Visual Normal per month
stairs (grease) walking,
conta- No damage
minated,
damage
3 Railings Damage Visual No damage per month
4 Connectio Visual, No loosening per week
n knocking correct

User’s Manual and Maintenance Manual Page 40 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

If you have any questions, please feel free to contact us any time!

We will reply as soon as possible.

The address and fax number show as follows.

SHANGHAI ZHENHUA Heavy Industry CO., LTD.

ADDRESS: 3261 Dong Fang Road, Pu Dong New District, SHANGHAI,
P.R.CHINA
POST CODE: 200125
TELEPHONE: 86-21-58396666
FAX: 86-21-58399555
86-21-58397000
E-MAIL: [email protected]
Internet Site: http://www.zpmc.com

User’s Manual and Maintenance Manual Page 41 of 41

 PORT SAID, EGYPT 9 RTG PROJECT

Appendix 1

Structural Part

1 General

The girder, gantry legs and sill beams of the Crane are of box-section
construction and the connections between them are welded. To avoid
deflection during shipment and erection both the supporting legs are
connected with a stay bar. Rail of square steel 80mmx80mm heavy type
is fitted on the girder. The rail is welded on the girder.

2 Major points in the painting procedure

All the plates are surface prepared to remove mill scales and then
coated with primer. After that the plates are cut and fitted-up and welded.
After the structural component is formed, it is post-treated (sand
blasted). All the surface of the formed component is coated with epoxy
zinc-rich primer, intermediate and finished paint. Internal surfaces of
box-section members are coated with anti-corrosion primer paint.

3 Maintenance Requirements

3.1. Regularly inspect the trolley and the rail operation condition and if
abnormal noise is found check the clip plate, the trolley wheels and the
shaft and keeper plate, etc.
3.2 Regularly check for deformation and welds of the trolley frame. Pay
special attention to the wheel shafts and take appropriate measures
immediately after any abnormal condition is found.
3.3 Frequently check the welds and the affected zone of the major
members. Pay attention to all support points and remedy defects
immediately after they are found. Check bolts for their tightening.
3.5 If a convex-concave surface is found on the box-section structure,
the Crane should be stopped and the cause should be examined and
removed.
3.6 Any damage to the paint on the structural members should be
immediately touched up.

1/2
 PORT SAID, EGYPT 9 RTG PROJECT

Inspected Inspection Inspection Inspection Inspection

Compone Items method and criteria period
nts
Sg. Descri Sg. Description apparatus
No. ption No.
Steel 1 Box-section Painting Visual, No large area per
struc- members telescope of peeling off season
ture
Welds Visual, No cracks,
telescope ultrasonic and
rulers X-ray test if
necessary
depth of
corrosion
<10% weld
height
Plate Visual, No cracks,
surface rulers local
deformation
<3%depth of
corrosion
<10%
2 Walkways Oil Visual Normal per
stairs (grease) walking, month
conta- No damage
minated,
damage
3 Railings Damage Visual No damage per
month
4 Connection Visual, No loosening per week
knocking correct

2/2