8.

2 MAINTENANCE

8.2.1 Maintenance Instructions

8.2.2 Maintenance - One Weekly Interval

8.2.3 Maintenance - One Monthly Interval

8.2.4 Maintenance - Three Monthly Intervals

8.2.5 Maintenance - Six Monthly Intervals

8.2.6 Maintenance - One Yearly Maintenance

8.2.1 Maintenance Instructions
The importance of on-going routine preventative maintenance cannot be over-
stressed. The benefits arising from a properly organised and scheduled
maintenance programme are three-fold:

1. Maintenance in itself ensures that the crane and its component machinery are
maintained in peak operating condition, thus ensuring minimum crane
operational downtime.

2. Machine and component inspection which form a large and crucial part of a
good maintenance programme, in many instances highlight potential problems
which though maybe not of immediate consequence, could prove to be
problematic in the long term.

3. Equipment functionality checks and tests are of extremely important

significance, particularly with respect to safety considerations. Cranes, which
feature many safety devices and features whose correct functionality while not
forming part of the normal operating cycle is imperative in maintaining safe
crane operation.

Maintenance should therefore, be considered as being a check to ensure correct

operation of the equipment, an inspection with a view to seeking potential
problems, as well as the routine maintenance, part replacement, etc. itself, - all of
which is necessary in achieving maximum crane up-time and prolonged problem -
free machine life.

The maintenance programme detailed in the following pages is provided as a

general purpose guideline and should only be used as such. It neither claims to be
totally comprehensive nor fully accurate in all details, with respect to any given
crane. Neither does it cater for any special or non-standard equipment or facilities.
It does however, provide a solid foundation on which a comprehensive
maintenance schedule for a particular crane may be built and/or customised.

It should also be noted that in particular the maintenance time intervals indicated
are approximate. In reality these intervals should depend on crane/machine usage
and therefore, may need to be up-dated accordingly.

The schedule is divided into a number of maintenance time intervals, i.e. three
monthly, yearly and three yearly.
Within each interval the crane is subdivided into a number of principle areas, e.g.
Hoist Drive, Trolley Drive, Auxiliary Systems, etc. The principle areas are in turn
subdivided into specific crane component parts, highlighting the particular
machine/component on which inspection and maintenance is to be carried out.
Instructions on the checks, adjustments, part replacements, etc. relevant to the
machine or equipment are provided.
8.2.2 One Weekly Maintenance Interval
Crane Area Crane Maintenance Instructions
Component
Spreader beam Limit Check adjustment and maintenance of
Switches all spreader beam limit switches.
Heater Check operation of spreader beam
hydraulic motor anti-condensation
heater.
Supply cable Inspect condition and anchoring of
spreader beam supply cable.
Plug / Socket Inspect condition of spreader beam
supply cable plugs / sockets.
 8.2.3 One Monthly Maintenance Interval
Crane Area Crane Maintenance Instructions
Component
Electrical House Ventilator Clean filter elements if fitted.
fans
8.2.4 Three Monthly Maintenance Interval
Crane Crane Maintenance Instructions
Area Component
Hoist Motor(s) Inspect stator and rotor, (marking, wear etc.)
Gear Clean motor and outside (dirt, grease etc.)
Drive Check operation of anti-condensation heating.
Inspect and lubricate bearings (as applicable).
Ventilator Clean filter elements.
Fan(s)
Drum limit Check adjustment and operation of all hoist
switch limit switches.
Up L.S. Check adjustment and operation of the up
emergency-stop limit switch.
Travel Motors Inspect stator and rotor, (marking, wear etc.)
Gear Clean motor outside (dirt, grease, etc.)
Drive Check operation of anti-condensation heating.
Inspect and lubricate bearings (as applicable).
Anti- Check adjustment and operation of all limit
Collision switches.
Beacons Check operation of devices.
Alarms
Trolley Motor (s) Inspect stator and rotor (marking, wear etc.)
Gear Clean motor outside (dirt, grease etc.)
Drive Check operation of anti-condensation heating.
Inspect and lubricate bearings (as applicable).
Trolley Check adjustment and operation of all trolley
Limit limit switches.
Switches Check adjustment and operation of fwd. / rev.
emergency stop limit switch.
8.2.4 Three Monthly Maintenance Interval
Crane Crane Maintenance Instructions
Area Component
Spreader Limit Check adjustment and operation of all spreader
Beam Switches beam limit switches.
Heater Check operation of spreader beam hydraulic
motor anti-condensation heater.

Supply Inspect condition and anchoring of spreader

Cable beam supply cable.

Plug / Inspect condition of spreader beam supply

Socket cable plugs / sockets.
L.V. Check operations of all L.V. Emergency Stop
E- Stop Stations.
Stations
8.2.5 Six Monthly Maintenance Interval
Crane Crane Maintenance Instructions
Area Component
Spreader Spreader Inspect cable insulation for wear (flat spots etc.)
Supply Cable or damage (cuts, cracks etc.)
Equipment Inspect cable anchor-clamp assemblies.
Inspect cable plug-socket assemblies.
Trim / List / Hydraulic Check operation of hydraulic motor anti-
Skew Motors condensation heating.
Energy Energy Check position and integrity of cable package
Chain Cables on chain.

Over-load Overload Check calibration of overload system.

System System Check operation of slack rope function.
Switch Panels Check operation of all anti-condensation
gear/ heaters.
Electronics Check operation of all electronic rack cooling
fans.
Auxiliary Lighting Check operation of all cabin / house lights.
Equipment Check operation of all access lights.
Check operation of all floodlights.
Check operation of all emergency lights.
Yodalarm Check operation with overload / push-button.
Telephones Renew batteries in all handsets / headsets.
Check operation of all handsets / headsets.
8.2.6 Yearly Maintenance Interval
Crane Area Crane Maintenance Instructions
Component
Switch gear Panels Inspect contacts on motorised switches and
/ Electronics check operation.
Inspect contacts on all main functions
contactors and check operation.
Check time settings on all timers and check
operation.
Check overload settings on all circuit
breakers.
Electrical / Panels Check / Tighten all electrical connections.
Electronic
panels /
Terminal
boxes
Control Control Reaffirm correct operation of all control
Consoles Consoles devices / indicators.