14 Practical Tips For Maintenance And

Operation Of Cargo Crane On Ships

Deck machinery and systems of ships are continuously subjected to harsh weather and corrosive
environment. Machinery such as cargo cranes and associated auxiliaries are important for
commercial ship operations, and any problem with them can lead to extended port stay, damage to
the property or even loss of life.

The deck crane, a necessary machinery on ship’s deck, does not only belong to navigating
officer’sworksheet. The ship’s marine engineer has to ensure that all the hydraulics and electronic
components of the crane are working efficiently and in coordination. The maintenance and smooth
operation of the ship’s cargo crane require teamwork of seafarers onboard the vessel.

A deck cargo crane mainly comprises of these sections and equipment:

Base Structure of the crane: The base structure of the crane is an extra strengthened structure, on
which, the pedestal of the crane is mounted.

Fixed Pedestal: This structure equally distributes the stresses to the base structure and also
incorporates the moving turrets via a slew ring connection to enable the rotational movement of the
crane

Moving Turret: Moving turret is where the operator’s cabin is situated, and the crane Jib is
connected to it. As per the make and design, the turret can move 360 degrees to its centre of
rotation.

Related Reading: 12 Important Checks For Deck Lifting Equipment On Ships

Jib Arm: The Jib arm is what carries the load. The arm can be hydraulically moved in four
directions- Up, down, back and forward. The moving turret performs the rotational movement of the
crane to transfer the load.

Hoist with wire: The hoist is hanged at the end of the Job arm with the use of steel wire ropes,
which are connected to the winch drum for lifting or lowering weight for transfer.

Related Reading: Understanding Lubrication Of Wire Ropes On Ships

Hydraulic and electric equipment: The hydraulics and electrical machinery are an integral part of
crane operation. Hydraulic oil pressure results in the movement of jib and turret, and winches do the
lifting of the load using hoist and wire. A small leak in the hydraulic line or problem in the winch
motor may stall the complete loading/unloading operation.
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Safety Devices: One cannot say a machinery is complete without any safety devices installed on it.
The deck cargo crane is provided with an emergency stop, overload protection, hydraulic oil filter
and level alarms, brakes etc. as safety devices.

The inspection and maintenance of the crane (including the base structure) are performed as per the
maker’s instruction and also included in the Planned Maintenance System (PMS) of the ship.

Related Reading: 20 Things That Should Be Included In Planned Maintenance System

To efficiently handle and maintain the ship’s crane, seafarer must know various tasks and essential
points associated with crane components as explained above.

Some important tips are for efficient operation, and maintenance of cargo crane on ships are:

1. In most of the bulk carrier ship, the crane provided on ship’s deck is for both hook operation
and grab operation. It is possible to have two different safe working loads for such cranes, i.e.
one for hook and another for grab operation. Ensure the SWL is displayed clearly in the Jib and
same is mentioned in the operator’s cabin to eliminate any confusion between two SWL.
Related Reading: 11 Steps To Enhance Safety Of Bulk Carrier Ships

Image credit: Sukhwinder Singh – Crane with Grab.

2. When handling the crane with a load which is near to its rated capacity, ensure to operate
with patience and extreme caution, especially when using lifting slings. If the rated capacity limiter
activates, the crane boom will suddenly stop causing the load to swing or bounce.
 3. During the stowed position, the hook of the hoist is clamped to a strong fixed point on deck.
Ensure when lifting the boom/jib, it has been unhooked, and the jib is free of obstructions
4. Never operate the Crane Jib below its lower limit with a load on the hoist, which can lead to
failure of the jib or slipping of wire from its drum.

Related Reading: Understanding Heavy Lifting Operation And Vessel Stability

5. Various limit switches are provided to restrict the movement of jib crane to its maximum
positions. Most of the cranes are provided with a key to bypass the limit switch for the jib. The
operator and chief officer must ensure the key is never left in the cabin of the crane once the
operation is finished. The key should be operated only under chief officer’s supervision, and crane
should be operated with utmost care.
6. Always check the base structure of the vessel before operating it for loosen foundation
bolts and cracks in the structure. When the crane is operating at its maximum load, the base
structure undergoes heavy stresses.
7. The base structure contains the rotational parts involving sheaves, bearings and slew rings etc.
They should be timely inspected to determine any wear on the parts. All these moving parts
and equipment must be lubricated correctly using the appropriate grease.
8. It has been reported in the past about the welding or other hot work carried by ship staff on
crane structure or jib. Never carry out any modification or welding job on crane structure or jib
without consulting the maker. It is a substantial load carrying machinery subjected to massive,
fluctuating loads. The crane parts are often made of a high-tensile material, for which
specialized welding and repairing procedures are needed. If the jib of the crane shows any
damage, it has to be reported to the owner and maker for getting the recommended repair
advice.

Related Reading: 20 Tips For Safe Gas Welding And Cutting Operations On Ships

9. When performing welding on crane parts such as a jib, parts carrying wire ropes etc., it is
recommended to disconnect the battery and switch off all the electronic control module and any
other electronic components provided in the crane.

Related Reading: How To Install Electronic Circuits On Ships

10. The most common failure related to the crane is the failure of wire ropes. The steel wire ropes
must be lubricated to all its length and especially in the way of sheaves when the crane is in the
stowed position. It is the responsibility of the Chief Officers to ensure all parts of the wire rope are
regularly inspected and dressed with lubrication. Lack of lubrication may increase the rate of
corrosion, leading to decrease in the elasticity, fractured strand, breakage of wire etc. The ancillary
parts for carrying the cable such as pully, winch drum must be greased to eliminate any rough
surface and friction.

Related Reading: Maintenance and Inspection Of Marine Wire Ropes For Better Performance

11. The ship staff has to timely check the condition of the hydraulic oil. The most common reason
for deck crane machinery failure is dirty hydraulic oil, leading to choking of filters. The oil should be
sent to shore for analysis at prescribed intervals of time to get the detailed analysis of the system
Related Reading: How to Test Lube Oil On Board Ship?

12. The brakes being the critical safety arrangement for the crane, has to be inspected at regular
intervals of time by checking the lining condition for its thickness. If disk brakes are provided,
clearance must be checks and the record to be added to the PMS file
13. Many times it has been observed onboard that the covers of the limit switch box or other
electrical connections are kept open all the time for the ease of checking. Always shut the
cover as it has a waterproofing arrangement which prevents switched from malfunctioning
during rainy weather.
14. Hydraulic leaks are very common in all types of cranes, whether it is onboard deck cargo crane
or a gantry crane in port. Never check the leaks using bare hands. Even a small hole will have
pressurised hydraulic oil coming out as a fine mist will penetrate and damage the skin, and
could do worse to human eyes. Always stop the operation, de-pressurise the line and then start
the repair work.

Related Reading: 8 Common Problems In Hydraulic Operated Common Valve System On Ships

Apart from the above maintenance and operating care, it is essential to follow the load test
requirements which is done every five years by a competent representative of a classification
society.

Disclaimer: The authors’ views expressed in this article do not necessarily reflect the views of
Marine Insight. Data and charts, if used, in the article have been sourced from available information
and have not been authenticated by any statutory authority. The author and Marine Insight do not
claim it to be accurate nor accept any responsibility for the same. The views constitute only the
opinions and do not constitute any guidelines or recommendation on any course of action to be
followed by the reader