Pacific Basin Training Seminar

2018 Cargo Gear Inspection and Maintenance

MHI/IHI CRANE

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Target in 2018?

2016:
Cargo gear issues ; 4% 2017:
1.79 days off-hires;
Issues in USWC: 4% (4
cases)
Issues in Australia: 0%;
Issues in NZ: 6% (2 cases);

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Principles of MHI/IHI crane hydraulic system

Inspection, adjustment and maintenance on MHI/IHI Crane

Summary Hydraulic oil management on board

Case study

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Principle of hydraulic system system

MHI Deck Crane

IHI Deck Crane

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MHI Hydraulic System Fleet Vessel: Mount Aso (2015)

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MHI Hydraulic System

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Major parts_ Hydraulic Pump
Part 1: Composite Hydraulic pump (3 stages pump)

Part 2 (Pos.10). Pressure control valve, setting

2.94Mpa

Part 3 (Pos.6). Coupler for luffing system pressure

test

1 Hoisting system speed control:

1. Light load (less 5mts): hoisting system pressure
is below 10.8 Mpa : 3pcs pump (052+052+025)

3 2 supply oil to hydraulic motor 1st stage.

2. Moderate load (5-12mts) Hoisting system

pressure is between 10.8Mpa and 17.5Mpa: 2pcs
pump (052+025) supply oil to hydraulic motor 1st
stage.

3. High load (more than 12mts) Hoisting system

pressure is over 17.5 Mpa : 2pcs pump (052+025)
supply oil to hydraulic motor 1st stage + sub
stage.
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Major Parts_ Hoisting Motor and Control Valve Block

Part 1: Auto change valve, setting: 17

Mpa, to control speed change over
from middle to low speed.
Part 2: 2 pcs Damper valves, normal
opening: 2-1/2 turns.

1 Part 3,4: Coupler, to check hoisting

pressure to 1 st main/sub Motor chamber.

5 Part 5: 2 pcs relief valves for Main/sub

2 motors, setting: 20.6Mpa.

4 3

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Major Parts_ Pressure Control Valve
Part 1 (Pos.4) Hoisting relief valve, pressure
setting:20.6 MPa
Part 2 . Coupler for Hoisting pressure check.

Part 3 (Pos.35) : Unload valve, pressure

setting:10.8 Mpa

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Hoisting System Speed Control

1. High speed with low load

-hoisting speed: 63m/min

-load <5T or System
pressure<10.8 Mpa)

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Hoisting System Speed Control
2. moderate speed with moderate load

-hoisting speed: 37m/min

-load <12T or
-System pressure<17Mpa)

Unloading valve (Pos.35) setting:

10.8Mpa

Unloading valve

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Hoisting System Speed Control
3. Low speed with high load

-hoisting speed: 18.5m/min

-load <30T or
-System pressure>17Mpa)

Auto Change Valve setting: 17Mpa

Auto Change Valve

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Slewing system_ CBV

Part 1 (Pos.29) : Counter Balance Valve for slewing,

Important:
the regulating bolt length should be confirmed when valve
renew.

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Hydraulic system unload

27

ACV

Pos. 27 Remote control valve (setting 5.39Mpa)

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Hydraulic system overload protection
4

75 74
72
MVHR &
MVHR2

PS2 Pos.74 overload under grab mode, setting: 16Mpa;

PS1 Pos.75 overload under hook mode, setting: 20Mpa;
Solenoid Valve 72 (MVHR): relief grab mode—Pos.73 remote control valve (17.5Mpa)
Solenoid Valve 72 (MVHR2): relief for overload protection (delay 1 second) under hook/grab mode.

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Hydraulic pressure check___Valve 4 setting
1. Connect pressure gauge to coupler 6
2. Start crane.

Coupler 6

3. Close stop valve (NO) for hoisting brake oil

4. Operate hoisting handle in hoisting down gradually.

5. Adjust pressure adjusting knob, till max. pressure as

Pressure setting knob
per manual (20.6MPa), then lock the knob.

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Hydraulic pressure check___Valve 35 setting

Pressure setting knob

Pressure setting check procedure:

1. Connect pressure gauge to “B”;

2. Start crane;
3. Close stop valve for hoisting brake;
4. Operate hoisting handle in hoisting down gradually;
5. Check pressure gauge reading, the Max pressure should be 10.8 Mpa. Otherwise, pls set it by adjusting knob of valve 35.

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Inspection and Adjustment___Operation handle & Micro switch

Handle at neutral position (both mic switches

not activated)

Crane start is available

Operate handle (1 pc micro switch activation)

Brake solenoid valve activation, brake release.

Important: To discuss:
1) To lubricate bush 12 ,13 & collar 10 periodically; 1) too close the cam,
2) big gap.
2) To renew the worn parts to obtain accurate control on micro switches.
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Check and adjust neutral position of control gear

how to check and adjust neutral position onboard?

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Defects on MHI Crane 1

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Defects on MHI Crane 2

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Hydraulic System

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Pressure hydraulic oil

Circulating oil
1
Returning oil

2
Hoisting working under light load (6Tons)
4
3 Line 05 ---From Aux pump;
5 Line 06,07 --- To brake control
system
No.1 ---1st stage speed change
valve (8-9Mpa)
No.2 --- 2nd stage speed change
valve(12-14Mpa)
No.3 ---Motor safety valve
(16Mpa);
No.4 --- CBV;
No.5 ---Cushion Valve.

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Pressure hydraulic oil

Circulating oil
Returning oil

Hoisting w orking under moderate load (18

Tons)

Line 05 ---From Aux pump;

Line 06,07 --- To brake control system

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Pressure hydraulic oil

Circulating oil
Returning oil

Hoisting working under high load (Max 30Tons)

Line 05 ---From Aux pump;

Line 06,07 --- To brake control system

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Pressure hydraulic oil

Circulating oil
Returning oil

Working Circle under Hoisting Dow n

Line 05 ---From Aux pump;

Line 06,07 --- To brake control system

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Major Parts in valve block

No.1– 1st stage SCV 3

No.2– 2nd stage SCV
No.3---Cushion valve
No.4--- CBV
1 No.5--- Motor safety
valve

2
5 4

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IHI pump assembly (old design)

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Pump Unit Assembly

New Design

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IHI Brake system inspection and adjustment

6mm ?

Lining thickness/mm Min. thickness/mm Max. stroke/mm Adjust stroke/mm

Hoisting Brake 6mm 40% original or 3.5mm 60mm 40-45mm
Luffing Brake 6mm 40% original or 3.5mm 60mm 40-45mm
Slewing Brake 6mm 40% original or 3.5mm 50mm 35-40mm

Important: improper adjustment can lead to initiation of brake band Office Feedback for Machinery Issue and Report Form
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Pressure check point for hoisting/luffing system
Luffing system pressure check point

Hoisting system pressure check point

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Inspect and adjust relief valve setting

Setting pressure of hoisting pump relief valve (17.2Mpa):

1) To fully tighten brake adjusting nuts;
2) To start crane, and operate hoisting-down, if brake is
slipped, re-tighten the brake;
3) To measure the pressure upon hoisting-”DOWN”;
4) If reset the relief valve, 1/8 turn adjustment for each
step till 17.2Mpa.
5) Then to check and set hydraulic motor relief valve to 16Mpa
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Check sprocket alignment

Important:
1) To focus on alignment of sprockets, the CE should attend shaft
alignment if overhauled motor or renewed pump, etc.
2) Chain coupling should be opened and refresh grease periodically.

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Check spline shaft (old design)

Reconditioned electrical rotor Corrosive and rusted spline coupling Pump spline shaft—worn off

Important:
1) The spline coupling to be well
greased periodically;
2) The spline coupling should be
inspected every 5 years.

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Hydraulic Oil Management

Oil Temperature control

Hydraulic oil quality control

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Hydraulic oil Management_ Temperature Control
1) Hazards from starting under low temperature (ambient temperature less than 20 deg.)
Low temperature will cause high viscosity, the oil fluid has big resistance and velocity will drop. The pressure drop will
increase when passing through suction filter, these will create local vacuum at pump suction port, and this is to say
deaeration/high cavitation of the fluid, then it will ruin the lubricity of pump. meanwhile, under heavy viscosity, the vanes can
stick and stay stuck in the rotor, the consequence is that there is no flow coming out of pump.

Maker Optimum Permit highest

viscosity Cst viscosity Cst

MHI 50-75 215

Operation Procedure in cold area:

1. Training crew on board prior to arriving at cold
area;
2. Keep space heating in machinery space, space
heaters or cargo lights to be used within 24hrs
prior to arriving;
3. Inching operation
4. Warm up oil pump, motor and pipeline
5. Keep crane operation during crane idle.

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IHI crane --- Temperature & Viscosity Range

IHI Crane:
1) Guarantee viscosity for
pump start up: 3000
mm2/s;
2) Optimum viscosity: 25-500
mm2/s,

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2) Hazards from hydraulic oil high temperature ( higher than 75 deg. Under high
ambient temperature):
• Hydraulic pump/hydraulic motor are badly worn out;
• High oil temperature causes oil seal failure due to aging NBR materials;
• High oil temperature will shorten rubber hose service life due to aging rubber materials;
• Reduced crane working efficiency due to increased internal leakage.

Troubleshooting and Countermeasure for high oil temperature:

• Restricted cooling air flow--- to open all vent ports;
• Contaminated oil cooler ---to flush oil cooler cooling fins by fresh water, specially operating
crane in high ambient area.
• Malfunction temperature control--- to keep crane idle running, and to calibrate temperature
control by portable infrared thermometer, confirm the setting point for cooling fan start/stop.
• Air mixed into oil system--- abnormal noise can be detected easily.

Important:
When crane is operating under high ambient temperature, cooling fan start/stop condition should
be confirmed at first working day, if oil temperature is still at high level (more than 60 deg.) even if
cooling fan is running continuously, then oil cooler should be cleaned immediately, or to inform
company/operation.

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Hydraulic Oil Management _Quality Control
1. Periodical particle count test

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Hydraulic Oil Management _Quality Control
2. To filtrate system oil periodically
▪ Use 6um portable filter;
▪ The line filter elements should be renewed every year;
▪ To flush and renew hydraulic oil if oil cleanliness is not much improved after filtrate via portable filter
or;
▪ Consider to install off-line filter (MHI) or Hyper filter(IHI)

IHI Hyper filter IHI--- Special filter for system flushing

MHI off-line filter

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Case Study

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Case 1: IHI Crane_ damaged hoisting pump and motor under high ambient temperature (47-48 deg.)
Problem statement:
1) Vessel arrived at Tuticorin/India for wheat discharge, where the ambient temperature is abt. 47-48 deg.
2) No.4 crane failed hoisting with abnormal noise from hoisting pump;
3) Ship staff renewed hoisting pump, but not rectified as no pressure build up; opened and inspected filter, found metal
particles; on load solenoid valve is working normally as per led indicator;
4) Further renewed the hoisting motor, and hoisting function is restored, but failed luffing as low pressure (less than
2MPa);
5) Maker technician attended vessel to further investigation, found max pressure in hoisting system is 25 MPa (which reset
by crew during troubleshooting), and abnormal noise from luffing/slew pump;
6) fully restored crane funcation after renewed luffing pump.

Investigation of root cause:

Sent hoisting motor and hoisting pump to maker for further investigation, and found:
A: Scope of hoisting motor damage:

Cam Ring--- deep scratch Vanes– chipped off (color changed) 3 pcs vanes seized inside rotor sliding slots
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AFT Casing--- deep scratches Fore Casing--- deep scratches Filter--- metal pieces on magnet
B. Scope of hoisting pump damage:

Cam ring found deep scratch 1 pc vane seized inside rotor Some vanes chipped off
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Cam Ring– worn out Rotor surface– worn out seriously Other view for rotor– worn out seriously
Root Cause:
1) Crane was running with high oil temperature under high ambient temperature (47 -48 deg) and with decreased cooling
capacity;
2) Colored vanes indicated “ burnt spot” result from broken oil film on cam ring due to low oil viscosity; or slight wear
occurred initially during last pump renewal due to no enough air purging, the metal particles will enter into hydraulic
motor;
3) The hoisting pump condition got worse under high oil temperature/low oil viscosity, which result pump lost power
gradually, crew tightened relief valve, try to increase power of hoisting pump, which much affected and caused hydraulic
motor overload till some vanes broke; as contribution factors, higher oil pressure/oil temperature in hoisting system
made it more worse.
Countermeasure:
1) To clean/flush oil cooler by fresh water, improve cooling capacity;
2) To filtrate oil periodically, improve oil cleanliness (less than NAS grade 12 ), or install super fine filter to improve oil quality.
3) Operate in tropical zone, keep good ventilation in machinery space;
4) To calibrate thermostats (cooling fan stop/start, high temperature alarm);
5) To check pressure setting of relief valve as per manual, don’t to adjust without pressure checking.
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Case 2. MHI--- No.4 Crane overload

Problem statement:
1) Frequent alarm activated (oil temperature high & motor overload) due to activated thermal relay
51M under both hoook/grab mode;
2) Working current would be over 400A when hoisting operation sometimes;
3) Checked Motor/contactor/slip ring/ACB,etc, found normal condition;

Root cause investigation:

1) Overhaul the unload valve 35#, 1 pc small spring missed ;
2) Overhaul the remote control valve 27#, the valve spool stuck.

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THANK YOU
if you have any question in crane, Pls send email to:
craneissues@pacificbasin.com

Prepared by Ai Weiguo

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