General Overhaul

For internal use only Check List PGO

Page 1

Check List
for
Partial
General
Overhaul of
Q Hoists
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9.10.2006PGO for Q hoists Check List

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 General Overhaul
For internal use only Check List PGO
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CONTENTS:
1 General............................................................................................................. 3

2 Preparations ..................................................................................................... 6
2.1 Tools needed ............................................................................................. 6

3 Maximum allowed number of braking actions.............................................. 7

3.1 Actions to be taken after this partial GO: ............................................... 9

4 Maximum allowed number of starts ............................................................. 10

4.1 Actions to be taken after this partial GO: ............................................. 10

5 Maximum allowed run time .......................................................................... 11

5.1 Actions to be taken after this partial GO: ............................................. 14

6 Maximum allowed number of control actions ............................................ 15

6.1 Actions to be taken after this partial GO: ............................................. 15

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1 General
As stated in the standard ISO 12482-1, the user/owner of a crane must keep
records of the usage of the crane.

The working conditions shall be recorded in one (or more) of the three ways
described below:

o Instrument recording: Hoist is equipped with a condition monitoring unit

(CID).

o Condition monitoring values can be used directly without any safety

factor.

o Logbook documentation together with suitable counters: Hoist is equipped

with a suitable counter (for time or distance), which allows the effective
operating cycles to be calculated. The hoist shall also be equipped with a
rated capacity limiter. User shall record the load spectrum.

o Condition monitoring values can be used with safety factor 1.2.

o Logbook documentation without counters: Hoist is not equipped with

condition monitoring devices. The user of the hoist documents the load
spectrum and the effective operating cycles.

o Condition monitoring values can be used with safety factor 1.4.

o Operating conditions are not known: Hoist is not equipped with condition
monitoring devices and there is not any reliable information of the
previous use of the hoist. Evaluation has to be done according to the
standard ISO 12482-1.

o Condition monitoring values can be used with safety factor 1.5.

Limits for runtime, starts, control operations and brakings for different condition
monitoring methods are shown in tables below.

Starts are the number of starts to up and down. In a case of control actions the
limit value is the number of make/break actions to up, down or fast whichever is
the highest.

When one of the condition monitoring values reaches the limit, check also the
other values. Also check the remaining SWP (Safe Working Period) of the whole
hoist. If they are near the limit, it should be studied whether it is more
economical to carry out several partial general overhauls or one universal
general overhaul.
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9.10.2006PGO for Q hoists Check List

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 General Overhaul
For internal use only Check List PGO
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Konecranes

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Table 1. Limits for run time, starts, control operations and brake SWP. Condition monitoring
method: CID.

Class Run time Starts Control Brake SWP

[h] actions [%]
1Am (M4) 6 300 1 134 000 640 000 0
2m (M5) 12 500 3 000 000 640 000 0
3m (M6) 25 000 7 500 000 640 000 0

Table 2. Limits for run time, starts, control operations and brake operations. Condition
monitoring method: Logbook and counters, uncertainty coefficient 1.2.

Class Run time Run time Starts Starts Control Brake

[h] [h] without with actions actions
without with counter counter
counter counter
1Am (M4) 5 250 6 300 945 000 1 134 000 533 300 833 300
2m (M5) 10 400 12 500 2 500 000 3 000 000 533 300 833 300
3m (M6) 20 800 25 000 6 250 000 7 500 000 533 300 833 300

Table 3. Limits for run time, starts, control operations and brake operations. Condition
monitoring method: Logbook, uncertainty coefficient 1.4.

Class Run time [h] Starts Control Brake

actions actions
1Am (M4) 4 500 810 000 457 100 714 200
2m (M5) 8 900 2 142 800 457 100 714 200
3m (M6) 17 800 5 357 100 457 100 714 200

Table 4. Limits for run time, starts, control operations and brake operations. Condition
monitoring method: Conditions are unknown, uncertainty coefficient 1.5.

Class Run time [h] Starts Control Brake

actions actions
1Am (M4) 4 200 756 000 426 600 666 600
2m (M5) 8 300 2 000 000 426 600 666 600
3m (M6) 16 600 5 000 000 426 600 666 600

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2 Preparations
Test the operation of the hoist. Drive the hoist up and down and the trolley forth
and back. Check also that the limits and emergency button operates properly.
Order necessary new parts before starting the work. After changing the new
parts, throw away the old parts in order to avoid their re-use.

2.1 Tools needed

Wrench + sockets
8, 10, 13, 17 and 24
Caliper
mm
Nm Torque wrench

Plastic hammer
Dial indicator
Steel hammer

Socket screw
HEX drivers 3, 5, 6 and 8 Pliers
mm

Puller (opening > 80

Marking pen
mm)
Screwdrivers of
different sizes
Circlip pliers
(phillips and
normal)
Mandrel/drift

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3 Maximum allowed number of braking actions

When the maximum allowed number of braking actions has been used following
operation must be done. CID warning: Warning Br SWP.

c_homo1e

4. Brake
5. Brake disc
6. Fixing screws for motor
7. Friction plate

Change always: Parts list number

The brake. See Spare Part Catalogue
The hoisting coupling.

Change the hoisting motor or Inspection method:

hoisting gear primary shaft if:
The splines of the motor shaft (either
brake or coupling splines) or the
splines of the gear primary shaft are
worn more than allowed.
Measurement. Compare the
contacting and non-contacting part
of the spline. If clear signs of wear
exist, replace the worn component. If
wear is doubted follow this instruction
for measuring the spline wear. There
is dimension over teeth to be
measured. See Table 5 and Table 6
for limit values. This can be done with
the help of a normal caliper if
performed carefully.

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! ORDER: Hoisting motor: See Spare Part Catalogue

! ORDER: Hoisting gear primary shaft: See Spare Part Catalogue

Table 5. Limits for the wear of the brake splines on motor shaft.

Motor MF10 MF11 MF13

Module [mm] 1.25 1.25 1.25
Number of teeth 18 26 26
New Wn max [mm] 13.48 17.35 17.35
New Wn min [mm] 13.46 17.32 17.32
Change limit in GO Wn [mm] 13.4 17.2 17.2
Final rejection limit Wn [mm] 13.3 17.1 17.1
Number of teeth in measurement 4 5 5
Wn

Table 6. Limits for the wear of the coupling splines on motor and gear shaft.

Motor MF10 MF11 MF13 MF13

Module [mm] 1.0 1.5 1.5 2.0
Number of teeth 23 18 21 18
New Wn max [mm] 7.66 6.98 11.47 15.23
New Wn min [mm] 7.62 6.94 11.43 15.19
Change limit in GO Wn [mm] 7.5 6.7 11.2 15.0
Final rejection limit Wn [mm] 7.4 6.5 11.0 14.8
Number of teeth in measurement 3 2 3 3
Wn
Change limit in GO Wn [mm]: shows the acceptable minimum value for the
parameter Wn when the shaft has to be changed in GO. The shaft has to be
changed in the GO if the value for the Wn is smaller than the change limit (it will
not last to the next GO).

Final rejection limit Wn [mm]: shows the absolute minimum value for the
parameter Wn. You do not need to use this in GO.

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3.1 Actions to be taken after this partial GO:

o Document all performed actions.

o CID: Reset the Brake SWP value by setting parameter 7-24 (Br Count: Brake
wear counter) to zero.

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4 Maximum allowed number of starts

When the maximum allowed number of starts has been used following operation
must be done. CID warning: Warning Starts.

4.1 Actions to be taken after this partial GO:

o CID: Change parameter 6-7 (Max ST: Maximum allowed number of starts)
with parameter 1-1-2 (Starts) increased by:

1-1-2 6-7

(M4, 1Am): + 1M134 =

(M5, 2m): + 3M000 =

(M6, 3m): + 7M500 =

Example: M4, 1Am

At the time of first GO (Warning when parameter 6-7=1M134):

o Parameter 1-1-2=1M137

The new value of parameter 6-7=(1-1-2)+1M134 =1M137+1M134=2M271.

At the time of second GO (Warning when parameter 6-7=2M271):

o Parameter 1-1-2=2M272
The new value of parameter 6-7=(1-1-2)+1M134 =2M272+1M134=3M406.

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5 Maximum allowed run time

When the maximum allowed run time has been used following operation should
be done. CID warning: Warning Run Time.

c_homo1e

1. Fan cover
2. Fan
3. Inspection opening for brake air gap
4. Brake
5. Brake disc
6. Fixing screws for motor
7. Friction plate

Change always: Parts list number

The motor bearings / the whole See Spare Part Catalogue
motor (See note below)
Sealings (on motor flanges).
The hoisting coupling.
Note! Changing the bearings requires special competence and tools. That is the
reason why bearing change is often unfeasible to perform on the site. It is
highly recommended to change the whole motor.

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Change the hoisting gear primary Inspection method:
shaft if:
The splines of the gear primary shaft Measurement. Compare the
are worn more than allowed. contacting and non-contacting part
of the spline. If clear signs of wear
exist, replace the worn component. If
wear is doubted follow this instruction
for measuring the spline wear. There
is dimension over teeth to be
measured. See Table 6 for limit
values. This can be done with the
help of a normal caliper if performed
carefully.
! ORDER: Hoisting gear primary shaft: See Spare Part Catalogue

Change the hoisting motor if: Inspection method:

The winding is damaged. Visual.
The coupling splines of the motor Measurement. Compare the
shaft are worn more than allowed. contacting and non-contacting part
of the spline. If clear signs of wear
exist, replace the motor. If wear is
doubted follow this instruction for
measuring the spline wear. There is
dimension over teeth to be
measured. See Table 6 for limit
values. This can be done with the
help of a normal caliper if performed
carefully.
! ORDER: Hoisting motor: See Spare Part Catalogue

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1. Limit switch
2. Gear wheel set
3. Cover
4. Base
5. Junction box

Figure 1. Measuring the wear of the plastic wheel

Change the limit switch if: Inspection method:

The wear in the plastic wheel is more Measurement. Remove the limit
than allowed. Change limit in GO switch. Measure the dimension w.
w>1mm. If the wear exists there has
been more resistance in rotating in
switch assembly than allowed.
If resistance exists, replace the limit
Testing. Rotate the switch wheel by
switch unit. hand. The rotating should be easy
with no significant resistance.
! ORDER: Limit switch unit: See Spare Part Catalogue

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5.1 Actions to be taken after this partial GO:

o Document all the provided actions.

o CID: Change parameter 6-9 (Max RT: Maximum allowed run time in hours)
with parameter 1-1-3 (Run Time) increased by:

1-1-3 6-9

(M4, 1Am): + 6 300 =

(M5, 2m): + 12 500 =

(M6, 3m): + 25 000 =

Example: M4, 1Am

At the time of first GO (Warning when parameter 6-9=6 300):

o Parameter 1-1-3=6 370

The new value of parameter 6-9=(1-1-3)+6 300 =6 370+6 300=12 670.

At the time of second GO (Warning when parameter 6-9=12 670):

o Parameter 1-1-3=12 700

The new value of parameter 6-9=(1-1-3)+6 300 =12 700+6 300=19 000.

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6 Maximum allowed number of control actions

When the maximum allowed number of control actions (see tables 1-4) has been
used following operation should be done. CID warning: Warning Control.

Change always: Parts list number

The direction (up and down), speed change and See Spare Part
brake contactors. Catalogue

6.1 Actions to be taken after this partial GO:

o Document all the provided actions.

o CID: Change parameter 6-19 (Max Control: Maximum number of Control)

with the maximum (value) of the parameters 2-7 (ST Up), 2-8 (ST down) or 2-
9 (ST Fast) increased by 640k0 (640 000).

Max (2-7, 2-8, 2- 6-19

9)

+ 640k0 =

Example:

At the time of first GO (Warning when parameter 6-19=640k0):

o Parameter 2-7=630k0
o Parameter 2-8=470k0
o Parameter 2-9=739k0

The new value of parameter 6-19=Max(2-7,2-8,2-9)+640k0

=739k0+640k0=1M379.

At the time of second GO (Warning when parameter 6-19=1M379):

o Parameter 2-7=1M260
o Parameter 2-8=940k0
o Parameter 2-9=1M478

The new value of parameter 6-19=Max(2-7,2-8,2-9)+640k0 =1M478+640k0=2M118.

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