Section 3: Maintenance instruction

ZPMC Cranes
ECT Delta Terminal • Cleaning
• Fastening
• Alignment
Maintenance Instruction

• Lubrication
• Inspection
Section 3:

Training course Page 1

 Cleaning
ZPMC Cranes
ECT Delta Terminal • Method of the cleaning:

1. Using the cleaner, usually good

Maintenance Instruction

for electric elements

2. Air compressor
3. Wire brush, Grinding
Section 3:

4. Machining: such as damaged

brake pad or disc

Training course Page 2

 Places Need To Be Cleaned:
ZPMC Cranes
ECT Delta Terminal • General:
1. Brake disc and pad
2. Filter of motors, fans
Maintenance Instruction

3. Oil of gearbox, hydraulic system

4. Clean the obstacles on the way of t
rolley and gantry.
5. Rail , rack-gear of elevator.
Section 3:

6. Gantry drive where is polluted by s

alt water.
7. Glass of windows of operator’s cab.
8. Display or indicator light

Training course Page 3

 Places Need To Be Cleaned:
ZPMC Cranes
ECT Delta Terminal
• Electric system:
1. Transformer inside, especially surface of
coiling
2. Keep e-room clearing. Do not keep the do
Maintenance Instruction

or open.
3. Electric elements inside the Control panel
shall be cleaned regularly.
Section 3:

• Hydraulic system:
1. Prevent the dust and other contamination
into the oil
2. Prevent air into or drain the air from oil.
3. Prevent humidity into or drain the water fr
om the oil
4. Checking and changing the filter of oil.

Training course Page 4

 Fastening
ZPMC Cranes
ECT Delta Terminal Comparing of the ISO and SAE bolts and nuts
ISO898-1 SAE J429 ISO898-2 SAE J995
Maintenance Instruction

Bolt Bolt Nut Nut

Grade 4.8 Grade 1 4

Section 3:

Grade 5.8 Grade 2 5 Grade 2

Grade 6.8 6

Grade 8.8 Grade 5 8 Grade 5

Grade 9.8 9

Grade 10.9 Grade 8 10 Grade 8

Training course Page 5

 Fastening
ZPMC Cranes
ECT Delta Terminal Visual inspection:
Maintenance Instruction
Section 3:

Training course Page 6

 Fastening
ZPMC Cranes
ECT Delta Terminal
Torque Wrench-For normal bolts:
1. Stow The crane 。
2. Marking the bolt and nuts. See figures right.
3. Apply a 75 ％ final tightening torque to the nuts.
Maintenance Instruction

4. Check If the nut is turning. In case of yes, marking

the loosing nuts so that it could be retighten later
or be changed.
5. If it is needed, the bolts and nuts shall be changed
with new ones.
Section 3:

6. Repeating 2)~5) to check all the rest bolts.

7. Retight all the loosing nuts according to the proce
dure given later.
8. Retight all the nuts that do not turning in step 3~4
according to following step 9~10.
9. Turn the nut anticlockwise about 30°to loosing the
nuts.
10. Retight the nuts to final torque.
11. Clean the surface and painting.

Training course Page 7

 Fastening
ZPMC Cranes
ECT Delta Terminal Frequency of inspection:

Inspection Frequency Frequency

（ First inspection （ After first insp-e
Maintenance Instruction

）* ction ）
Visual 3 month （ except special 6 month （ except speci
area ） al area ）
Torque Six month or 50000 cycle 5 、 15 、 25 、 30 、 35y
Section 3:

Wrench ， 10 ％ spot check ears after operating

Changing the When it is need When it is need

bolts

Training course Page 8

 Fastening
ZPMC Cranes
ECT Delta Terminal Standard of changing the bolts:
• Damaged, deformed, corrosive, or the surfa
ce roughness various much.
Maintenance Instruction

• For structure bolts according to GB1228 、

GB1229 、 GB1230 ASTM325 、 ASTM490 o
r other equal standard, normal the galvaniz
ed bolts could not be re-used after finally ti
Section 3:

ghten.

Training course Page 9

 Fastening
ZPMC Cranes
ECT Delta Terminal Tighten the bolts-normal bolts:
1. Check to make sure the bolt is in not polluted and in good condition.
2. Clean the dirt from surface between washer and structure. The surfa
Maintenance Instruction

ce shall be level.
3. Clean the bolts and nut if necessary.
4. Set the washers so that it could well against bolt head or nuts.
5. Apply a torque with 75% of final toque. For the connection of flange,
pay attention to the order of tightening to guarantee the bolt is loade
Section 3:

d evenly. Usually tightening start and spread from the most rigid poi
nts and spray .
6. Apply 100% final toque to the bolts. The tighten bolt shall be marked
with different colors for 75% torque and 100% torque)

Training course Page 10

 Fastening
ZPMC Cranes
ECT Delta Terminal Tighten the bolts-structure bolts:
1. All the bolts in a replacement job shall come from a single production batch.
This is guarantee the uniform friction properties.
2. Make sure there are sufficient number of bolts with correct grade. All of
Maintenance Instruction

those much be changed at the same time. The torque wrench shall be
verified.
3. Check to make sure the bolt is not polluted and in good condition.
4. Clean the dirt from surface between washer and structure. The surface shall
level.
Section 3:

5. Clean the bolts and nut if necessary.

6. Loosing one bolts and nuts completely and replace it with new one and
apply a 75% final torque. Make sure only one bolt and nuts are removed.
Replace all the bolts one by one.
7. The removed bolts shall be damaged to prevent re-using
8. Apply 100% final torque to the bolts. The tightened bolt shall be marked with
different colors for 75% torque and 100% torque.( Pay attention to the
sequence of tightening.)

Training course Page 11

 Fastening
ZPMC Cranes
ECT Delta Terminal Tightening sequence (example of flange connection):
Maintenance Instruction
Section 3:

Training course Page 12

 Fastening
ZPMC Cranes
ECT Delta Terminal Anti-loosing:
Maintenance Instruction
Section 3:

Training course Page 13

 Alignment
ZPMC Cranes
ECT Delta Terminal
Standard of Elastic Coupling Alignment
Maintenance Instruction
Section 3:

Training course Page 14

 Alignment
ZPMC Cranes
ECT Delta Terminal Coupling Δr （ m Δb Δa （ m
Location
m） m）
GT motor coupling elastic ≤0.05 0.06 mm ＝ Δr
Maintenance Instruction

MH drum coupling gear --- 10’ ---

BH drum coupling gear --- 10’ ---

Section 3:

Training course Page 15

 Alignment
ZPMC Cranes
ECT Delta Terminal
Standard of Lamidisk Coupling Alignment
Maintenance Instruction
Section 3:

Training course Page 16

 Alignment
ZPMC Cranes
ECT Delta Terminal
• Use the laser concentricity measuring instrument
Maintenance Instruction
Section 3:

y
x
z

Training course Page 17

 Alignment
ZPMC Cranes
ECT Delta Terminal • Use an dial indicator gauge
Maintenance Instruction

1. Set the gauge: gauge base is placed on one side of the coupling and t
Section 3:

he hand shall contact the outer ring of the other coupling.

2. Initially, reset the reading to zero. So the values can be read after turni
ng 270 (please note the positive and negative signs). Then got δ90°,δ
180°, δ270° , Δry=δ180°/2
3. The circumferential jumping value in the horizontal direction is ΔrZ=δ9
0°-δY270° 。 Max valueΔr=
4. Same as shown in the above drawing, make the hand contact the sho
ulder surface of the other coupling and adjust the value to zero. After t
urning 270, two angular deviations in the vertical and horizontal axial
directions can be read. Got δ90°,δ180,δ270 first, thenΔay= δ180° ， Δ
ay= δ90°-δ270° ， by=arctgΔay/r ， Δbz=arctgΔaz/r.

Training course Page 18

 Lubrication
ZPMC Cranes
ECT Delta Terminal
• Lubricant-Gear oil

Viscosity Manufacture’s product pour flash po Location Code

cSt/ 40 name point int
(mm2/s) C C
Maintenance Instruction

ISO 220 Shell Omala* -18 238 Gantry, Boom A1

VG Shell Omala LPP -27 210 hoist gearbox.
320 Shell Omala HD -48 245 Spreader,
Mobil Mobilgear 630 -24 240 Gantry cable
Section 3:

Mobil Mobilgear XMP -24 272 reel gearbox

Mobil Mobilgear SHC X -45 244
MP
ISO 320 Shell Omala* -18 238 Main hoist, A2
VG Shell Omala LPP -27 210 trolley
320 Shell Omala HD -45 242 gearbox
Mobil Mobilgear 632 -18 265
Mobil Mobilgear XMP -18 268
Mobil Mobilgear SHC X -38 242
MP

* Used after leaving factory

Training course Page 19

 Lubrication
ZPMC Cranes • Lubricant-Hydraulic oil
ECT Delta Terminal

Viscosity c Manufacture’s product pour flash po Location Code

St/ 40(m name point int
m2/s) C C
Maintenance Instruction

ISO 46 Shell -30 218 Pump station in B1

VG Shell Tellus S -39 246 side machinery
32 Shell DTE 20 -30 218 house, backreac
Mobil DET 10M -27 232 h, Gantry wheel
Section 3:

Mobil DTE Excel -42 216 brake station.

Mobil -33 226

Training course Page 20

 Lubrication
ZPMC Cranes
• Lubricant-Grease
ECT Delta Terminal
NLGI Manufacture’s product dropping working Location Code
Grade name point temperature
C C
Maintenance Instruction

1 Shell HDX2* 185 -20~+100 Heave load sliding b C1

Mobil Mobilux EP 1 190 -25~+120 earing ： equalizer b
eam shaft, boom hin
ge and etc.
Slow speed anti-frict
Section 3:

ion bearing: bearing

s of durm shaft, shea
ve bearing…

1 Shell HDX2* 185 -20~+100 Wire rope C2

Shell Malleus GL 190 -25~+120
Mobil Mobilux EP 1
1 Shell Alvania RL1 180 -30~+120 Motors(also ref. man C3
2 Mobil Mobil Polyrex 288 uals of motor)
EM

Training course Page 21

 Lubrication
ZPMC Cranes
ECT Delta Terminal
• Oil sample test -tools
Maintenance Instruction
Section 3:

Training course Page 22

 Lubrication
ZPMC Cranes
ECT Delta Terminal
• Oil sample test- procedure
Maintenance Instruction

1. install the 2. Put the 3. Draw the

bottle to the pipe into the sample oil
Section 3:

pump pump into bottle

4. uninstall the 5. Put the label on the bottle

bottle and close and record the information
the cover of bottle such as: date, location...

Training course Page 23

 Inspection
ZPMC Cranes • Inspection of abnormal temperature rise, noise, vibration.
ECT Delta Terminal

 Abnormal temperature may caused by:

1. Improper lubrication
2. Improper gear meshing
Maintenance Instruction

3. Bearing clearance is too loose or too tight (or bearing

damage)
4. Brake not fully released or not centered (one side
released but the other side still touching the disc)
5. Hydraulic thruster oil internal leakage
Section 3:

6. Abnormal operation of the relief valve

 Abnormal noise may caused by improper gear meshing,

bearing damage, loose bearing clearances, shaft bending,
loose bolts, interference or motor fan damage, lack of
lubrication, etc.
 The Abnormal vibration may caused by improper gear
meshing and lack of adequate rigidity of the installation
base
Training course Page 24
 Inspection
ZPMC Cranes • Other Inspection items.
ECT Delta Terminal

1. Crack (To be discussed further in Structure)

2. Rail and rail clamps
3. Check wear of drum, sheaves, support rollers, slap block.
Maintenance Instruction

4. Check spreader, cargo beam hook

5. Check brake such as wear of pad or brake disc, functions, limit
switch, alignment
6. Check wear of shaft, sleeves, key
Section 3:

7. Inspection of structure
8. Safety device, limit switch.

Training course Page 25

 Inspection of Gantry Rails
ZPMC Cranes 1. Straightness
ECT Delta Terminal
- Measured by a transit or piano wire
- δ1=±10mm

2. Span
Maintenance Instruction

- Measured by a steel tape measure of IS

O class 1 or equivalent
- δ2=5 mm, S =61000mm
Section 3:

3. Height difference between rails

- Measured by a transit
- δ3 ＝ H0±15mm (H0 ： is original dock d
esign high difference ＝ 390)

4. Bend of rail left and right

- Measured by a transit or piano wire LH+
RH<Tolerance
- δ4 ＝ ±20 mm

Training course Page 26

 Inspection of Gantry Rails
ZPMC Cranes 5. Levelness
ECT Delta Terminal - Measured by a transit
- δ5 ＝ ±25 mm. In the nominal span and w
heel base of the crane no point on any ra
il will be greater that ±25mm out of the c
Maintenance Instruction

ommon plane established by the other th

ree corners of the crane.

6. Inclination
- Measured by a transit
Section 3:

- ≤1/400 (Check every 10m/32.81ft)

7. Joint Elevation difference

- Measured by a steel ruler
- δ6 ＝ ±0.5 mm

8. Joint gap & deviation

- Measure by a steel ruler
- δ7 ＝ ±0.5mm,d8 ＝ 6mm (In summer )

Training course Page 27

 Inspection of Trolley Rails
ZPMC Cranes 1. Slope or grade
ECT Delta Terminal - Measure by a transit or a water level
- Less than 1/200:In the area without camber where there is no trolley o
r in the area with camber when there is trolley with rated load
- Mainly for fabrication but only for reference to check the deformation
Maintenance Instruction

of the structure after crane had been used for years

2. Span (S)
- Measured by a steel ruler
- δ 2=5mm, S=6000mm
Section 3:

3. Height difference
- Measure by a transit or a water level
- δ3=9mm

4. Bend of rail left and right

- Measured by a transit or piano wire
- δ4=10mm

Training course Page 28

 Inspection of Trolley Rails
ZPMC Cranes 5. Joint difference in Elevation
ECT Delta Terminal
- Measured by a steel ruler
- δ6 ＝ ±0.5 mm
Maintenance Instruction

6. Joint Different in gap

- Measured by a steel ruler
- δ7 ＝ ±0.5mm,d8 ＝ 4mm
Section 3:

7. Offset of the rail and rail support beam

- Measured by a steel rule
- δ9≤t/2 ＝ ±6mm

8. Levelness
- Measure by a transit or a water level
- δ10≤6 (0.1% of span)

Training course Page 29

 Inspection and adjustment of the Rails
ZPMC Cranes • Force on rail:
ECT Delta Terminal
Maintenance Instruction

• Check Wear of rail:

Section 3:

• The tolerances specified above apply to new crane tracks. If in

the course of use, those tolerances are exceed by 20%, the
track must be realigned. If the traveling behavior is noticeably
deteriorating, it may be necessary to realign the track, even if
the tolerance exceed has not reached 20%.
Training course Page 30
 Installation of rail Clips
ZPMC Cranes 1. Weld the Bottom plate.
ECT Delta Terminal
using a low hydrogen electrode . The botto
m plate shall be tightly clamped to prevent
any movements during welding
Maintenance Instruction

2. Clean
Section 3:

3. Install the bolts

Pay
attention
to the
direction
of mark

Training course Page 31

 Installation of rail Clips
ZPMC Cranes 4. Install the upper plate
ECT Delta Terminal
- With a hammer, bring the upper part of the clip in firm contact with the
rail
- full tight the bolt to 150Nm
Maintenance Instruction

- Paint finally
Section 3:

Training course Page 32

 Check Wear of Gantry Wheels
ZPMC Cranes
ECT Delta Terminal
Maintenance Instruction

Original
Item Wear limitation (mm)
(mm)
Section 3:

780 or has 0.2% *D different

D (Driving
800 D’ between driving and idle
wheel)
wheel
D (idle 780 or has 0.5% *D different
800 D’
wheel) between two idle wheels
h 25 h’ 38
b 147 b’ 165
a 26.5 a’ 17.5

Training course Page 33

 Check Wear of Trolley Wheels
ZPMC Cranes
ECT Delta Terminal
Maintenance Instruction

Original
Item Wear limitation (mm)
(mm)
Section 3:

615 or has 0.2% *D different

D (Driving
630 D’ between driving and idle
wheel)
wheel
h 25 h’ 32.5
b 125 b’ 140
a 27.5 a’ 20

Training course Page 34

 Check wear of sheaves and drum
ZPMC Cranes Sheaves Drum
ECT Delta Terminal
1. See below drawing 1. See below drawing
2. Sheave Seriously Imprinted 2. Drum grove Seriously Imprinted
Maintenance Instruction
Section 3:

Training course Page 35

 Inspection of hook
ZPMC Cranes 1. Any bending or twisting by 10.
ECT Delta Terminal
2. Any distortion causing an increase in
throat opening of 15%.
3. Any wear exceeding 10% of the original
section dimension of the hook or its load
Maintenance Instruction

pin.
4. Any self-locking hook that does not lock.
5. Any latch that does not close the hook’s
throat.
Section 3:

6. Repair of cracks, nicks and gouges shall

be carried out by designated person by
grinding longitudinally; following the
contour of the hook provided no
dimension is reduced by more than 10%.

 Zone A and B is most important area need

to by inspected

Training course Page 36

 Inspection of twist lock
ZPMC Cranes 1. Any cracks, damages or permanent def
ECT Delta Terminal
ormation
2. Wear at the head fo twist lock
3. Cracks and deformations at the area of sc
Maintenance Instruction

rew.
 Zone A and B is most important area ne
ed to by inspected
Section 3:

Training course Page 37

ZPMC Cranes
ECT Delta Terminal
Maintenance Instruction
Section 3:

Training course Page 38