4 CRANE OPERATION

4.1 General ................................................................................................. 4 3

4.2 Crane Safety ......................................................................................... 4 3

4.3 Description of Safety Equipment........................................................... 4 5

4.4 Cabin .................................................................................................. 4 14

4.5 Check Lists .......................................................................................... 4 21

4.6 Operating Instruction.......................................................................... 4 24

4.7 Lifts..................................................................................................... 4 25

4.8 Crane Shut Down and Out of Operation Condition.............................. 4 26

4.9 Hoist Winch Emergency Load Lowering Procedure.............................. 4 27

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FIGURE LIST

FIGURE 4.1 – JOYSTICK LAYOUT ............................................................................. 4-5

FIGURE 4.2 – LUFF RATCHET ASSEMBLY ............................................................... 4-6
FIGURE 4.3 – ALARM ANNUNCIATOR PANEL .......................................................... 4-7
FIGURE 4.4 – CABIN LAYOUT.................................................................................. 4-14
FIGURE 4.5 – CONTROL PANEL LAYOUT .............................................................. 4-15
FIGURE 4.6 – GAUGE PANEL LAYOUT ................................................................... 4-17
FIGURE 4.6 – OPERATORS SEAT LAYOUT ............................................................ 4-19
FIGURE 4.6 – JOYSTICKS MOTIONS CONTROLS ................................................. 4-20
FIGURE 4.9 – EMERGENCY LOWERING PUMP AND BALL VALVE ...................... 4-27

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4.1 General
This section of the manual covers operations and safe use of the crane.
The crane operator should read through this section to gain a basic understanding of
crane operation and safety, before attempting to operate the crane. This section covers
routine operations, heavy lifting safety precautions as well as emergency procedures.
By reading though this section the crane operator should become familiar with the safety
equipment available to ensure the crane is operated safely.
Instructions on the operations of the crane are also explained to familiarise the operator
with this particular crane.

4.2 Crane Safety

Detailed and comprehensive hazards identification, assessment and control measure
document has been included in Section 10. All personnel involved in the maintenance
and operation of the crane should be trained in the identification of these hazards and the
appropriate methods of their control.
Listed below are some of the more significant safety precautions extracted from a
general Crane Risk Assessment that the crane operator should observe.

Prior to Crane Operation

1) Only qualified operators should be permitted to operate the crane. Thorough
training in accident prevention is essential. For further operator requirements,
refer to Section 2.1 & 3.1.2 of the latest edition of API Recommended practice 2D
(Recommended practice for operation and maintenance of offshore cranes.
2) Unauthorised personnel should be prevented from gaining access to the crane.
3) The operator must be physically and mentally fit, to operate the crane.
4) The crane must be operated by a person who is familiar with this crane's
limitations, safety equipment and operating instructions.
5) The directions of your local inspection authority concerning the operation of this
equipment should be posted inside the control cabin.
6) Never alter any equipment or change any pressure settings without prior written
permission from FFC.
7) Never heat, weld or oxy-cut on the boom sections or any other structural
components without prior permission and procedures given by FFC.
8) Strictly adhere to the daily check list in this section to avoid untimely crane shut
down or failure.
9) The operator should be instructed to check the operation of the main hoist, fly
hoist and luff brakes, as well as the luff ratchet.

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10) The operator should be instructed to report any occasion when a rope becomes
kinked or displaced from a sheave or rope drum. This situation requires careful
checking of the rope. Operations should stop if a dangerous condition exists.
11) Report any cases of excessive wear, faults, unusual noise or other irregularities
immediately.
12) The crane should only be serviced when out of operation.
13) Keep the equipment in a clean condition to avoid accidents.

During Crane Operations

These are some of the safety precautions the crane operator should observe.
1) Ensure the crane has sufficient fuel and oils to prevent unexpected shutdowns
when working.
2) DO NOT operate the crane if any limits or safety equipment are out of order.
3) The crane should NOT be operated in winds exceeding speed of 27.5m/s
(including gusts). Immediately lower all loads, and stop using the crane.
4) Under strong wind conditions bulky loads should be handled with care.
5) NEVER divert your attention while operating.
6) Pay attention to the appointed signalman.
7) DO NOT start crane operation until signalman or load is in full view.
8) OBEY an emergency signal at any time no matter who gives it.
9) If there is any doubt as to safety, refuse to handle loads until safe conditions exist.
10) Conveyance of persons on the hook is PROHIBITED.
11) Control levers must be operated steadily at all times.
12) Observe engine tachometer during operations to avoid stalling or load run-away.
13) NEVER lift a load in excess of the rated load capacity chart. Pay attention to the
overload system.
14) DO NOT use limit switches as stopping devices.
15) DO NOT lift more than one separately rigged load at a time.
16) DO NOT leave the operating seat when a load is on the hook or with crane
running.
17) DO NOT load fly hoist (if fitted), when a load is on the main hook, and vice versa.
18) NEVER swing a load over people. Use the warning horn.
19) Use tag lines for handling bulky loads.
20) Dragging heavy loads along the ground is a dangerous practice and is prohibited.
21) Once the hook has reached a landing, STOP hoisting down. This is to avoid
slackening of the wire rope, which may result in the incorrect re-reeling on the
winch drum.

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4.3 Description of Safety Equipment

General Description
Motion control levers provided in the cabin consist of a joystick type controls

Figure 4.1 – Joystick Layout

All controls increase the speed of each motion proportionally to the deflection of the
levers from the neutral position.
All control levers are of the 'deadman' type which spring return to the
neutral position upon their release.
The slew brake is operated manually by a button on the joystick. The slew brake should
only be applied when boom is to be held in position during heavy winds.
The main hoist, fly hoist and luff brakes are released whenever the motion control levers
are moved from the neutral position. These brakes automatically apply when the control
levers are returned to neutral.

Operational Display (SLI)

The operational display indicates the current crane configuration, hook position and
current hook load. Operators can also view engine status, hydraulic status and current
wind speed.
Visual and aubible warnings for crane overload, engine and hydraulic faults are also
provided. See SLI manual for more detailed information.

Boost Pressure Switch

When boost pressure drops excessively (or is lost) the boost pressure switches stop all
motions and apply all brakes (except slew).

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Emergency Stop
This is a palm push lock down button mounted on the operator's control panel and
powerpack. When activated, it shuts down the crane engine, ahich applied all drive
brakes.

Luff Drum Pawl

This provides a positive mechanical lock on the luff drum and engages with engine
shutdown.

LS5

Figure 4.2 – Luff Ratchet Assembly

Pressure Cut Off (PCO)

The hoist and luff pumps are fitted with a PCO, which de-strokes the pumps when the
system reaches the maximum set pressure.

Motion Stop Limits

As crane motions approach the working limits, the available maximum speed will be
reduced then stopped when working limit is reached.

Luff in Deceleration and Stop

When the incoming boom trips the deceleration and motion stop limit valve, luff motion
automatically decelerates and stops.

Alarm Annunciator Panel

The Annunciator panel provides engine and hydraulic system warning with visual and
audible indication.

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Figure 4.3 – Alarm Annunciator Panel

No. Description No. Description

1 Fuel Level Low 9 Boost Pressure Low
2 Air Start Pressure Low 10 Ultimate Limit Hoist/Fly/Luff
3 Gearbox Oil Temp High 11 Engine Over speed
4 Hydraulic Oil level Low 12 Engine Coolant Temp High
5 Main/Fly Hoist up Limit 13 Engine Oil Temp High
6 Main/Fly Hoist down Limit 14 Engine oil Pressure Low
7 Luff In/out Limit 15 Engine Oil Level Low
8 Slew Limit 16 Air Inlet Shutoff

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No. Description No. Description

17 Exhaust Temp High 25
18 Fuel Tank Level High 26
19 Spare 27
20 Spare 28
21 Spare 29
22 Spare 30
23 Spare 31
24 Spare 32

The annunciator has a test button to allow the operator to check the alarm and indicators
at any given time during crane operation. If the annunciator is activated, stop crane
operation and rectify the problem before resuming operation.

Boom Buffer

This provides a load on the boom at minimum radius to ensure that a slack luff rope is
not possible at absolute minimum radius. The boom buffer has a RED marker, which
must be always visible.

The boom buffer piston should never be compressed beyond the RED
marker into the buffer cylinder. Serious damages to the boom
assembly will occur.

RED Marker
Buffer
support In Extreme
RED
chain Position
Front marker
Mast
Leg

Boom Boom
Buffer Buffer
Cylinder Piston

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Limit Switches & Alarms

Hoist (main and fly)

The hoist limit switch is operated through the shaft on the drum gearing. The limit switch
automatically resets when the motion is driven in the opposite direction.
The up limits must be set with the boom at maximum radius and starting with the up limit.
The up working limit is set approximately 3 metres below the boom head. The hoist up
motion applies the hoist brakes. When reached it stops.

A minimum of five full turns of rope must remain on the drum at the
lowest hoist down point.limit.

Luff

Like the hoist limit switch, the luff limit switch is operated on the drum gearing.
The luff out limit is set at maximum radius. When triggered it stops the luff down motion
and applies the luff brakes.
Luff in ultimate limit stops the motor and all crane motions. If this limit is tripped, the
reason must be determined by a qualified person and rectified before the limit can be
bridged over and the crane restarted. Error! Reference source not found.

Luff Down Override

This switch is a key type. It is used to park the boom in the boom rest. It also bypasses
the maximum working radius for maintenances.

Overriding limit switches should only be for maintenance purposes,

NOT for handling loads.

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The luff can be overridden with the following method:

The ‘Luff Out Override’ key switch is located on the drivers console inside the Cabin.

The Luff Out Override switch can only be operated with a key, the key has to be turned to
the ‘ON’ position and held as the crane operator luffs the boom out beyond normal
operating range. Before luffing the boom to the park position, make sure there is enough
rope paid out on the Fly and Main hoist so the hook does not hit the head sheaves.

Lowering the Boom

1. Ensure there is no load on the hooks and there is sufficient rope paid out
(2m to 3 m) from the head sheaves.
2. Turn the ‘Luff Out Override’ and hold in ON position.
3. Gradually Lower the Boom to the Park position. Refer to the General
Arrangement drawing for details on boom park positions and boom angle.
4. Once the boom is parked, switch OFF the crane.

The annunciator and other warning devices may trip during the boom lowering.

Raising the Boom

1. Switch the crane ON. The annunciator and other warning devices may be
active.
2. Gradually raise the boom. Acknowledge annunciator and other warning
devices as the boom travels inside the limits.
3. Test Luff limit switch
4. Remove the Luff Out Override key from the switch

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Reeving Switch

The “Reeving Switch” key switch is located inside the Electrical box behind the operator’s
seat. It is recommended that Reeving switch NOT to be used when parking the boom for
daily maintenance. It should be used for changing ropes on the winch drums.
The Reeving switch, once switched ON, will enable the operator to override Main & Fly
Slack limits, Hoist Up limits and Luff Out Relay. The boom lowering procedure is same
as Luff Override procedure except the key does not have to be held in the ON position.
(Some reeving switches may be spring-loaded and have to be held in the ON position
while reeving is in progress.)

Always ensure the Reeving Switch is in the OFF position after reeving
and the key is removed from the switch. Operating the crane while the
reeving switch is in the ON position will cause serious damages to
the crane.

Geared Cam Limit Switch

Snap action switches with change over function are operated by maintenance free
moulded gears.
Switches as well as reduction gears, reduction being selected to suit maximum drum
turns, are housed in a reinforced polycarbonite enclosure with IP66 protection.
Adjustment of the limit switch is infinitely made on the cam disc by means of a self-
locking worm gear.
Worm gear is operated by either a 10mm screw driver or 4 mm Allan key.

Only the white worm gears are used to adjust limit switch position.,

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Block adjustment

The planetary gear construction allows a block adjustment in addition to individual

contact adjustment from the usable revolution 6.5. The final gear stage is also provided
with an adjustable worm, coloured black. All cam discs can be commonly adjusted by
means of this adjusting worm.

Standard cam discs are supplied with 20 rises. The following picture is an Illustration of
the geared cam limit switch.

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Anti Cavitation Pressure Switches

These instantly stop all motions when boost pressure is lowered excessively (or lost) and
automatically apply the hoist and luff brakes. Refer to hydraulic circuit for pressure
setting.

Multi Disk Drum Brakes

All the Drum drive units are equipped with fail safe wet disk brakes.

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4.4 Cabin
Refer to the Cabin Assembly drawing in section 6 for more details

Cabin Layout

000

H O U R M ET ER

1/2
E F

Figure 4.4 – Cabin Layout

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Control Panel

The Control Panel provides the operator with a visual indication of the crane’s conditions
and switches to safely operate the main hoist and auxiliary winches. The control panel is
shown below:

RPM

Figure 4.5 – Control Panel Layout

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No. Description No. Description

1 Phase Power 1, 2, 3 13 Luff Out Override
2 Indicator light (Slew, Luff, 14 Slew Limit Override
Hoist, Fly, Luff ratchet)
3 Pneumatic/Hydraulic Start 15 Engine Messenger Display
Selector
4 Engine Ignition 16 SLI Display
5 Lamp Test 17 Annunciator
6 Engine Start 18 Top Wiper/Washer
7 Main/Fly Hoist Selector 19
8 Engine Stop 20
9 Slew Brake Selector 21
10 Horn 22
11 Emergency Stop 23
12 Engine Throttle

1. Electrical Power Status: Are located on the control console in the cabin.
They are the indicator crane AC power status.
2. Slew Brake Applied is a visual indicating light to signal that the slew brake is
applied
3. Luff Brake Applied is a visual indicating light to indicate luff brakes are
applied on the luff drum via the drive assembly.
4. Main Hoist Brake Applied is a visual indicating light to indicate main hoist
brakes are applied on the main hoist drum via the drive assembly.
5. Luff Ratchet Applied is a visual indicating light to indicate Luff ratchet is
engaged on the luff drum. The luff ratchet is applied only when there is a loss
of hydraulic pressure or when the engine is shutdown.
6. Fly Hoist Brake Applied is a visual indicating light to indicate main hoist
brakes are applied on the main hoist drum via the drive assembly
7. Pneumatic/Hydraulic Start Selector switch is used to select between
pneumatic and hydraulic start.
8. Ignition & Start key switch activates crane controls and allows engine to be
started.
9. Main/Fly Hoist Selector switch is used to select between auxiliary and main
hoist winch operations.
10. Stop: switch is used to stop the engine
11. Slew Brake Switch is a selector switch that will apply brakes on the slew
drive.
12. Warning Horn To warn all the personnel near crane.
13. Emergency Stop is a push button switch that shuts down the crane. Brakes
on the winch drums will be automatically applied.
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14. Hand throttle lever operated hand throttle for diesel engine. Use the
tachometer to adjust engine speed.
15. Luff Out Override key switch allows the crane operator to lower the boom
beyond the normal operating range for maintenance purposes only. The luff
out override key should be kept with the crane supervisor.
16. Slew Limit Override key switch allows the crane operator to operate in ‘No
Go Zone’ area. The slew limit override key should be kept with the crane
supervisor.
17. Engine Messenger Display is a visual indicator to indicate status of the
engine eg RPM
18. SLI Display is a visual indication of SWL, radius
19. Top Wiper/Washer is a switch to operate the top wiper and washer
20. Annunciator refer to previous section for Annunciator Panel

Gauge Panel

The gauge panel provides the operator with visual indication of the crane’s condition. The
panel instrumentation consists of actual gauges indicting operating parameters.

000

HOUR METER

1/2
E F

Figure 4.6 – Gauge Panel Layout

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No. Description
1 Engine Oil Temperature
2 Hydraulic oil Temperature
3 Hours Run Meter
4 Engine Oil Pressure
5 Fuel Level
6 Engine Water Temperature
7 Air Pressure
8 Slew Pressure
9 Luff Pressure
10 Boom & Control Pressure
11 Hist/fly Pressure

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Operator’ Seat

Figure 4.7 – Operators Seat Layout

Right Controller Joystick operates the Fly and Hoist winches. The Fly and Hoist selector
switch located on the Control Panel is used to activate either winch.

Backward Motion will Forward Motion will

raise the hook lower the hook

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Left Controller Joystick operates the Luff and Slew Motors. Forward and backward
motion controls the Luffing of the boom, while left and right motion controls the slew
rotation.

Left & Right Up & Down

Slew Luff

Figure 4.8 – Joysticks Motions Controls

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4.5 Check Lists

Daily
According to the usage of this crane, "daily check list" means inspection either by
the crane operator or the maintenance personnel whenever the crane is to be
operated.
It is imperative that the crane operator is informed by the previous operator or the
person responsible for the crane of any shut down or problem.
It must be noted, that the following daily checks do not include all specific directions
given for the diesel engine. Refer to engine manual for this information.
Check Prior to Engine Start:
Item Check Prior to Engine Start Check
1. Check for sufficient fuel oil to avoid untimely engine shut down
during operation.
2. Check engine radiator coolant level and for evidence of leaks
3. Engine air cleaner service indicator
4. Check pump drive gearbox and/or gearbox oil level for
evidence of leaks

Do not overfill

5. Check hydraulic oil level tank level.

Do not overfill

6. Visually check for oil leakage around the Power Pack and the
winch.
7. Visually check for leakage or damage in the air and non-
mechanical systems.
8. Check hoist, luff and fly ropes for defects.
Ensure that ropes are lying correctly in all sheaves and drums.
The ropes shall be free of kinks, loose strands or rust.

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Engine Start:
Warm up diesel engine as recommended in the engine manual supplied, and then
continue with checks. Drive all motions at half speed only while checking, as the
hydraulic system needs warming up.
Do not lift any loads while the hydraulic system is below operational
temperature.

Item Start Instruction Check

1. Reset circuit breakers, if disengaged, to supply electric power
to the engine and crane safety system (if applicable)
2. Reset emergency stop button (if latch down type is used)
3. Shift throttle control to low idle and then turn start key and push
start button. Allow the engine to warm up as recommended in
engine manual
4. Should the engine fail to start, rectify possible cause
Do not attempt lift any loads until Warm Up
checks are complete

Checks During the Warm Up Period (Prior to Operation):

Item Checks During Warm Up Check

1. Check filter visual indicators, replace elements if required.
2. Check hydraulic pipe work for leakage.
3. Check oil levels (Engine and hydraulic drive units)
4. Drain water from air tank and filter.
5. Check engine tachometer.
6. Check safe load indicator and run a comparison with the
mechanical radius indicator on the boom.
7. Release slew brake.
8. Check main hoist deceleration and working limit function
9. Check boom buffer positions. Both buffers must be of equal
length when the boom is away from them.
10. Check luff deceleration and working limit function.
11. Check horn.
12. Check all controls spring return to neutral position.

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13. Check that there is absolutely no motion creep with brakes

applied.
If any motion is detected, immediately shut down
the crane and contact qualified maintenance
personnel.
14. Check engine throttle control and tachometer when engine oil
is sufficiently warmed up.
15. Check oil tank temperature before any heavy work is required.
The minimum temperature shall not be less than 25-35
degrees Celsius, depending on the oil type.
16. Check engine oil level (dipstick).
17. Check to ensure operational display visual and audible alarms
are working.
18. Check the fuel gauge in cabin.
19. Check that load chart for applicable boom length is installed in
the cabin.
20. Check hoist brake.
21. Check emergency stop is working.
22. Check 'luff down' limit
23. Check emergency lowering needle valve(s) is present and
tightly closed.
24. Ensure windows are clean.
25. Determine that wind is not excessive for crane use and type of
lift.
26. Check aviation warning light(s) are working.
27. Visually check for loose, missing, or corroded bolts, pins,
keepers or cotter pins.
28. Visually check loose gear to be used, such as slings, sling
hooks and shackles (if applicable).

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4.6 Operating Instruction

Prior to starting the diesel engine and during the warm up period, the operator is required
to check the crane according to the daily checklist.
When the crane is assembled for the first time, circuit breakers in the electric cubicle
must be engaged to provide power. The safe operational display is also switched on
through the ignition switch and shows boom radius, load in tonnes and permitted load in
tonnes.
When the crane is started with cold and thick hydraulic oil in the system, the filter bypass
alarm may sound until the hydraulic oil warms up.
When hoisting loads the first load of the shift must be raised a short distance from the
ground held for a moment then the lift can continue; this also must occur for the first lift
greater than 50% of the rated capacity.
Winch speeds are in direct proportion to the deflection of the joystick from the neutral
position.
Care must be taken at all times to ensure that all motion controls are operated smoothly
and progressively and not 'plugged' or 'counter switched' before the load stops.
Example – Pull the lever from zero to approximately half stroke and a pressure between
5 and 18 bars actuates the pump from zero to full displacement. The rest of the valve
stroke, giving a pressure of 18 to 28 bares de-strokes the hydraulic motor towards its
minimum displacement if the load on the hook allows. Adjustment within the motor is
automatic towards the faster speed, if the torque required is satisfied. This only applies to
the main hoist and luff motions.
The operational display continually shows the radius, actual and permitted load at any
specific radius and must be observed at all times. When overload condition occurs, the
operator should immediately luff in or lower the load to the ground.
Further information on the operational display can be found in Section 9 of this manual.
All crane alarms are provided as an operator’s aid only and should not be solely relied
on. The operator should be aware at all times of the permitted safe working load, the
current load on the hook and the current radius.

Slew Brake Control

During normal operation, the brake switch is in the OFF position (brake open). If during
windy conditions the boom must be held in its position for a prolonged period, the switch
can be moved into the ON position (brake closed).

Do not apply the slew brake while the crane is slewing.

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4.7 Lifts
All lifts are undertaken by observing the safe load indicator for the hoist in operation.
Check the load tension by pulling the joystick slowly in the up direction. Release lever
immediately when either load indicator shows overload.
If the indicator shows overload, then the load must be lightened, or the lifting radius
reduced.
Pay strict attention to the safe load indicator when luffing out with a
heavy load to avoid overloading the crane.
When raising heavy loads the control shall be pulled slowly to accelerate the load to the
maximum available hoist speed.
The engine high idle RPM may drop by 10% under maximum load
conditions
Lowering speeds for heavy loads (above ¾ full load) should be limited to about half of full
speed by reducing both engine speed and pump stroke control.
If during operation a further drop is observed, immediately back-off the controls to avoid
stalling of the engine.
During lowering of a load or the boom, to avoid serious damage to mechanical
components, the operator must ensure engine RPM does not rise above maximum.
Immediately back off motion control when overspeed alarm sounds
Should a load or the boom ever accelerate out of control, never
counter switch controls, let all controls go and hit the emergency
stop button to arrest load or boom.
Observe Tachometer

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4.8 Crane Shut Down and Out of Operation Condition

Engine and hydraulic components should be allowed a sufficient "cooling off" period prior
to shutdown.
Running engine at approximately half speed for at least 5 minutes after crane has been
working hard should be sufficient for cooling off purposes.
Before leaving the cabin, ensure that all windows are closed. Switch off all lights and shut
cabin door securely.
Before leaving the crane, a visual check of components should be undertaken and the
maintenance supervisor or the responsible person informed of any discrepancies.

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 Pedesal Crane Model 20/10K, Serial N0. 1676
IOM – Section 4. Crane Operation
4 27

4.9 Hoist Winch Emergency Load Lowering Procedure

In case of crane prime mover tripped and unable to restart in safe condition, the load on
the hook must be lowered manually. This is crucial if the situation cannot be rectified in a
short period.
Check regularly that the emergency lowering needle valves are closed
tightly. Loss of performance and overheating will occur if the valves
are slightly open. Familiarise yourself with the location and operation
of these emergency lowering valves.
Proceed as follows for the hoist in operation:
1) Connect hose from hand pump to hoist brake.

Figure 4.9 – Emergency Lowering Pump and Ball Valve

2) Fully open the emergency needle valve on the pump/motor.
3) Turn emergency lowering ball valve to supply pressure to winch brakes.
4) Pump open the brakes until the load lowers slowly.
5) If the load lowers too quickly immediately release pressure to the brakes at
hand pump with release valve.
6) Repeat procedure until load is safely on the ground.
7) Disconnect hand pump and securely close needle valve.

The brakes are fail-safe (spring on), with hydraulic pressure release.

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5 MAINTENANCE
5.1 Preventative Maintenance General..................................................... 5 3

5.2 Detailed Maintenance Schedule............................................................ 5 4

5.3 Recommended Oils and Greases ......................................................... 5 14

5.4 General Rope Care .............................................................................. 5 19

5.5 Service and Repair of Structural and Mechanical Components............ 5 27

5.6 Service and Repair of Fluid and Electrical Components ....................... 5 29

 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-2

FIGURE LIST

FIGURE 5.1 – ENGINE OIL DIPSTICK AND FILTER .................................................. 5-4

FIGURE 5.2 – TYPICAL WINCH DRIVE ASSEMBLY .................................................. 5-6
FIGURE 5.3 – SLEW DRIVE ASSEMBLY.................................................................... 5-7
FIGURE 5.4 – DISC BREAK MAINTENANCE ............................................................. 5-8
FIGURE 5.5 – PUMP DRIVE GEARBOX (TYPICAL) ................................................... 5-9
FIGURE 5.6 – OPEN GEAR....................................................................................... 5-10
FIGURE 5.7 – SPLINE LUBRICATION CHAMBERS ................................................. 5-11
FIGURE 5.8 – HYDRAULIC OIL FILTER CROSS SECTION..................................... 5-13
FIGURE 5.9 – CORRECT SPOOLING FROM REEL TO DRUM ............................... 5-20
FIGURE 5.10 – VALLEY BREAK ............................................................................... 5-21
FIGURE 5.11 – CORRECT METHOD OF MEASURING ROPE DIAMETERS .......... 5-22

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-3

5.1 Preventative Maintenance - General

This section of the manual covers routine maintenance recommendations for the
crane.
The owner must establish a regular maintenance schedule, suited to the specific
application and local conditions, using this manual as a guide in conjunction with
component manufacturer's manuals.
It is recommended that the owner of this crane clearly defines the responsibilities of
the crane operators (drivers) and the maintenance personnel.
As experience is gained by the owner, and operating schedules established, the
following recommended procedures and checks should be modified to suit the
operating pattern.
For this reason, specific quantities and times are not specified for normal
maintenance procedures, eg. greasing, fuelling, inspections, etc. These
requirements should be determined by observation, and practical application of
established maintenance procedures.
A maintenance log book should be used to establish the required schedule. This log
book should contain the SLEW RING CLEARANCES record.
In later sub-sections, we recommend periodical checks, lubrication schedule and
system maintenance. These are based on an annual usage of 2000 hours.

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-4

5.2 Detailed Maintenance Schedule

Thorough Examination
A thorough examination of the crane should be carried out after the initial 100 hours
of operation. Refer to maintenance log in Section 9.
Bolts, screws and hydraulic fittings should be checked and re-
tightened if necessary.
For recommended bolt tightening torques, refer to Section 9.

Diesel Engine

Figure 5.1 – Engine Oil Dipstick and Filter

General engine check during maintenance:
1. Oil filter
2. Fuel filter
3. Coolant level
4. Drive belt tensions
5. Electrical leads and hoses
6. Oil leakages
7. Battery condition (if any)
Detailed maintenance instructions for diesel engine must be taken from supplied
Engine Manual.

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-5

Hydraulic System
Maintenance of the hydraulic system mainly involves changing the oil and oil filter
elements. Typical system maintenance checks are:
Check for the filter bypass warning light on the annunciator panel after the warm
up period.
Check tank oil level regularly.
Top up with correct oil as specified.
Do not overfill hydraulic oil tank, as the oil might overflow through
breather during operation.
Use clean oil receptacles.
Check filler breather on tank for clogging.
Check the system instrumentation i.e. ensure pressure gauges, etc., are
functioning satisfactorily.
After each 100 hours operation or during general service of crane, drain off 1 litre
of oil from tank to remove any condensed water. If water is present, drain until
removed and top up with clean oil.
Frequency of hydraulic oil change depends on the cleanliness of the oil. Compare
tank oil with a sample of new oil and if in doubt ask a hydraulic oil supplier for
assistance in evaluating suitability of oil for further use.
Check for external leaks. Immediately repair any leaks discovered.
Check that pipe-work is sound. Where rubber hose is used, ensure that no chafing
has occurred.
Check that all system pressures are normal for the application.
When a maintenance shutdown occurs it is advisable to examine the oil tank for
sludge and foreign matter, and completely clean if necessary. This is imperative if
a component failure has occurred.

Pneumatic System (If Applicable)

Maintenance of the pneumatic system is relatively similar to hydraulic system, mainly
involves checking connection, air dryer and filter elements. Typical system maintenance
checks are:
Check receiver tank regularly for structural integrity.
Check connection for air leak.
Check air receiver for any condensed water.

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-6

Planetary Gearboxes (Motion Drives)

The first oil change must be carried out after the initial 50-100 hours of operation, with
subsequent changes every 2000 hours or 12 months, which ever occurs first. These
intervals may be modified, depending on actual operating conditions.
During oil change, we recommend that the inside of the gearbox is flushed
out with flushing fluid recommended by the lubricant manufacturer. Check
that there are no metallic parts with unusual dimensions in the magnetic plug
of the gear unit or any multi-disk brake.
Oil should be changed when hot to prevent build up of sludge deposit.
Oil levels should be checked once per month.
When checking oil levels in gear units equipped with a multi-disk
brake or hydraulic motor, if the levels have risen, this means that oil
is penetrating either from the brake seals or from the motor rotary
seal.
If more than 10% of total oil capacity has to be added, check for oil leaks.
Oil level on horizontal mounted boxes is on the centreline.
Vertical mounted boxes (slew drives) are filled to the top through the Expansion
tank as follows:
o Remove Expansion tank plug
o Fill until oil reaches the minimum mark.
o With the gear running under steady steady-state thermal condition and the
oil at its expansion, add oil to the maximum, but not exceeding maximum
mark.
o Run the gear until all air pockets are eliminated.
Due to the lesser usage, change oil in slew drives once every year.

Figure 5.2 – Typical Winch Drive Assembly

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-7

EXPANSION TANK
HYDRAULIC
MOTOR

BRAKE FILLER

BRAKE
RELEASE
PORT

GEARBOX

SLEW PINION

Figure 5.3 – Slew Drive Assembly

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-8

Disc Brakes (part of planetary gearboxes)

Figure 5.4 – Disc Break Maintenance

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-9

Pump Drive Gearbox

The first oil change must be carried out after initial 200 hours of operation, with
subsequent changes every 2000 hours or every 12 months, which ever occurs first.
These intervals may be modified, depending on actual operating conditions.
1) During oil change, we recommend that the inside of the gearbox is flushed out
with flushing fluid recommended by the lubricant manufacturer.
2) Oil should be changed when hot to prevent build up of sludge deposit.
3) Oil levels should be checked once per week.
4) If more than 10% of total oil capacity has to be added, check for oil leaks.
5) If oil level rises, pump shaft seal or engine seals may be faulty and must be
replaced.
6) Oil level is indicated by the maximum notch on the measuring stick (part of
breather) of the oil tank.

FILLER BREATHER

A4VG180

A4VG180

DRAIN PLUG
Figure 5.5 – Pump Drive Gearbox (Typical)

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-10

Open Gears
Grease open gears with the recommended compounds avoiding bare metal to metal
contact. For best result, apply with brush sparingly to avoid dripping or splattering.
Lubrication should be checked weekly.

Figure 5.6 – Open Gear

Slew Ring
Lubricating intervals depend on the operating conditions. This is generally every 100
operating hours for ball bearings, or every 50 operating hours for roller bearings.
The grease filling is there to reduce friction, seal the bearing and provide protection
against corrosion. Therefore, the bearing must always be greased liberally so that a collar
of fresh grease forms around the whole circumference of the bearing gaps and seals.
The bearing should be rotated during re-lubrication.
During periods of down time (3 months), the crane should be slewed to form a collar of
fresh grease around the slew ring circumference. This is to ensure fresh grease forms at
the seals and the bearing gaps around the slew ring. Grease until fresh grease oozes
from seals.

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-11

Maintenance / Inspection of Splined Pinion Drives

Crane is fitted with splined pinion drives on the main, luff and slew drives; these must be
inspected prior to erection of the crane and repeated every 4,000 working hours, or every
two years, whichever occurs first. Failure to do so can result in the premature failure of
the winches on the crane. The following is a procedure for inspection of the pinion spline.
For standard gearbox / pinion arrangement:
i) Remove the pinion from each gearbox output shaft.
ii) Wash down and clean the male and female splines and inspect for wear.
iii) Hand fit the pinion to the shaft and rock the pinion backwards and forwards as
per normal rotation. Any movement greater than 1 mm at the outer edge of the
teeth of the pinion indicates the pinion and/or the gearbox output shaft must be
replaced. Any visual sign of significant corrosion or wear also indicates that the
pinion and/or gearbox shaft must be replaced.
iv) If the pinion and the gearbox shaft wear are within limits, refit the pinion, and
ensure oiler is connected and charged with oil
v) Repeat the procedure for each pinion.
Internal splines on winch pinions are designed as a wet connection and are fitted with
spline lubrication containers. These should be periodically (approximately every 8
working hours) run to maintain a film of oil. Failure to do this may cause the pinion to
seize to the gearbox shaft.

Figure 5.7 – Spline Lubrication Chambers

Wire Ropes
Use compound when necessary to prevent corrosion. Check weekly.

Bearings and Bushes

Refer to Lubrication Diagram for locations and greasing intervals.

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-12

Unpainted Components
Unpainted parts of the crane, such as shafts and pins, are generally treated with anti-
corrosion coating. It should be inspected on a regular basis and preserved with a spray-
on coating.

Sheaves (Mast, Bridle, Boom and Hook)

Grease sheave bearings.
Check for bearing wear and nylon ring covers every 250hrs.
Check sheave rotation and wobble
Check sheave root and root flanges for normal wear.

Fuel Filter and Water Separators

The contamination level of the fuel governs how often maintenance is required to drain
water or to replace the filter element. Drain the collection bowl before contaminants reach
the bottom of the turbine or when the water detector (optional) indicates it is time to ‘drain
water’. Inspect or drain the collection bowl of water daily and replace the element every
500 hours, every other oil change or if a power loss is noticed, whichever comes first.
If a vacuum gauge has been installed on the outlet side of the filter, change the element
between 6” (152.4 mm) to 10” (254 mm) of mercury (restriction). Note that the actual
measurement varies in different fuel systems. Always carry an extra filter element as one
tank-full of excessively contaminated fuel can ruin a filter.
To Drain Water:
Open the self-venting drain to evacuate contaminants. If necessary, remove the lid and
prime the unit by filling with clean fuel. Replace the lid and tighten the T-handle snugly by
hand ONLY.
To Replace the Filter Element:
Only use genuine filter elements.
A convenient moulded handle on the top of the element simplifies removal. Remove the
lid and then remove the element by slowly pulling upward on the moulded handle with a
turning motion. Replace the lid gasket with the one supplied with the new element. Apply
a coating of clean fuel to the seal prior to reassembly. Fill the bowl with clean fuel, then
replace the lid and tighten the T-handle snugly by hand ONLY. Start the engine and
check for leaks. Correct any leaks with the engine off.

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-13

Replacing Filter Element

Element Removal and Cleaning
1) Ensure that the oil supply lines to the filter are closed and the line
decompressed to atmosphere.
2) Drain the filter of oil by removing the bowl, which is threaded into the housing.
Unscrew by applying the correct spanner to the base hexagon.
3) Lower the bowl vertically to clear the element assembly, which will remain in
the housing.
4) Dislodge the element from the housing. Remove carefully.
5) Paper elements cannot be cleaned, and must be replaced. Cranes fitted with
washable elements should be cleaned appropriately before replacing the
element.
Fitting the Clean Element
1) Before replacing the element, thoroughly clean the interior of the bowl and the
accessible areas of the housing. Replace element, wire only, ‘O’ ring seal and
lubricate.
2) Push the element spigot into the housing until it holds in place.
3) Replace bowl rim seal and lubricate housing and bowl before refitting bowl.
4) Screw the bowl rim seal and lubricate the housing and tighten with the correct
spanner.

Figure 5.8 – Hydraulic Oil Filter Cross Section

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-14

5.3 Recommended Oils and Greases

Hydraulic System Oil
For optimum performance and service life of hydraulic axial piston pumps and motors,
and fixed displacement pumps and motors, the viscosity is to be 30 centistokes (30cst) at
60ºC.
FAVELLE FAVCO recommends using hydraulic oil with an ISO viscosity class VG68;
with a viscosity index of a minimum of 95 is suitable for tropical conditions or for areas
with high ambient temperatures.
For areas where the ambient temperature falls below zero or day time ambient
temperature is between 0ºC to maximum of +20ºC, a thinner oil as ISO - VG 46 or 32
must be used. Recommended oils and operating temperatures:
Approx. Ambient Below 0 - +20 C +10 -+35 C
Day Time Temperature 0 C

Hydraulic Oil: ISO Class VG 32 VG 46 VG 68

Oil should be exchanged and stored in clean drums for future use before ambient
temperatures fall below 0ºC and the allowable viscosity of the oil in the system rises
above 1000cst.
For cranes in low temperature (0ºC to -10ºC) condition only: provision to fit low wattage
heaters into hydraulic oil tank must be made. The warm oil will only benefit the pumps
when started, while the control, brake and safety system oil remains in freezing
environment and will operate sluggishly and could lead to a dangerous condition.
In any case, oil must be warmed up to a minimum temperature as shown on following
table before full pressure operation can commence.

Viscosity Oil Temperature

Oil must be heated to reach 1000cst -10 C -5 C 0 C
minimum of
Preferred minimum starting state 600cst -5 C 0 C +5 C
Minimum full pressure working state 100cst +20 C +27 C +33 C
Optimum working state 30cst +40 C +50 C +60 C
Maximum working state 20cst +50 C +60 C +70 C
Short time peak temperature 15cst +60 C +70 C +80 C
(critical)

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-15

Pump Drive Gearbox (if Applicable)

Gearbox manufacturer’s recommendation: SAE 90 with EP additives. Oils meeting this
recommendation are:

Ambient -20˚C/+5˚C +5˚C/+40˚C -30˚C/+65˚C

Temperature (-4˚F/41˚F) (41˚F/104˚F) (-22˚F/149˚F)
VG 100 VG 150
Viscosity – ISO 3448 VG 150-220

Viscosity – Ivmin 95 95 165

Mobil SHC 629
Mobilgear 600
MOBIL Mobilgear 627 Mobilgear SHC
Mobilgear XP220
150
AGIP Blasia 100 Blasia 150 Blasia 220
BP MACH GR XP 100 BR XP 100 SGR XP 220
CASTROL Alpha SP 100 Alpha SP 150 Alpha SN6
ELF Reductelf SP 100 Reductelf SP 150 Oritis 125 MS
ESSO Spartan EP 100 Spartan EP 150 C. Oil Lg 150
I.P. Mellana 100 Mellana 150 Telesia Oil 150
SHELL Omala Oil 100 Omala Oil 220 n/a
TOTAL Carter EP 100N Carter EP 150 na

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-16

Planetary Gearboxes (Motion Drives)

Gearbox manufacturer’s recommendation: ISO viscosity. Class: VG150 (V.I. 95 min.).
Oils meeting this recommendation are:

-20˚C/+5˚C +5˚C/+30˚C -30˚C/+50˚C -30˚C/+65˚C

Lubricant
IV 95 min IV 95 min IV 95 min IV 165 min
ISO 3448 VG 100 VG 150 VG 320 VG 150-220
AGIP Blasia 100 Blasia 150 Blasia 320 Blasia S 220
ARAL Degol BG 100 Degol BG 150 Degol BG 320 Degol GS 220
Enersyn
BP MACH GR XP 100 GR XP 150 GR XP 320
HXT220
CASTROL Alpha SP 100 Alpha SP 150 Alpha 320 Alpha SN 150
Non leaded Non leaded Non leaded
CHEVRON n/a
gear gear gear
Compound Compound
Compound 100 n/a
150 320
Spartan EP 100 Spartan EP Spartan EP Excolub SLG
ESSO
150 320
Q8 Goya 100 Goya 150 Goya 320 EL Greco 220
Telesia Oil
I.P. Mellana 100 Mellana 150 Mellana 320
150
Glygoyle 22
MOBIL Mobilgear 627 Mobilgear 629 Mobilgear 632 Glygoyle 30
SHC 630
SHELL Omala Oil 100 Omala Oil 150 Omala Oil 320 Tivela Oil SA
Carter EP
TOTAL Carter EP 100N Carter EP 150 n/a
320N
Synteso D220
KLUEBER Lamora 100 Lamora 150 Lamora 320
EP
Elf ORITIS
Reductelf SP Reductelf SP Reductelf SP 125 MS
ELF
100 150 320 Elf Syntherma
P 30

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-17

Disc Brakes (Part of Planetary Transmission Gearboxes)

Manufacturer’s recommendations: Hydraulic Oils, ISO class: VG32. Mineral oils with
enhanced heat and aging resistance and viscosity ISO VG 32, with a viscosity index
greater than or equal to 95. Alternative Oil: Auto transmission fluid, SAE Grade: 10W.
Oils meeting this recommendation are:
Manufacturer Oil Designation
Esso ATF Dexron II
Mobil ATF 220

Grease Points (Nipples Provided)

Grease must contain an effective corrosion prevention additive and must be consistent
after extreme periods of service. FAVELLE FAVCO recommends a Lithium based EP 2
grease to be used in slew bearing. Greases meeting this recommendation are:
Manufacturer Grease Designation
Castrol EPL2
Esso Beacon EP2
Mobil Mobilux EP2

If the slew ring bearing grease contains MOLYBDENUM DISULPHIDE

then the molybdenum content must not be greater than 3%

Open Gear Teeth

This compound is to be highly water resistant and of an adhesive nature. Greases
meeting this recommendation are:
Manufacturer Grease Designation
Castrol Molub-Alloy 936
Esso Surett Fluid 4K'
Mobil Mobiltac 375NC
Shell Cardium Fluid C

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-18

Sheaves
The sheaves are fitted with grease nipples or greased through sheave pin. The root of
the sheave can be lubricated with rope lubricant. Greases meeting this recommendation
are:
Grease
Manufacturer
Designation
Castrol EPL2
Esso Beacon EP2
Mobil Mobilux EP2

Ropes
The type of lubricant and frequency of application varies with rope construction, the
operating conditions and its functional application. The lubricant must provide protection,
against wear, corrosion and minimise internal friction between wires and strands while
the rope is in service.
The rope must be cleaned of moisture, residual lubricant and contaminants before
applying clean lubrication. Recommended rope lubricants:
Lubricant
Manufacturer
Designation
Rocol RD105
Lanotec Wire Rope Lube

Engine Lubrication Oil

For detail recommendations refer to separate 'Engine Operators Handbook'.
Approx. Ambient Below 0 - +20 C +10 -+35 C
Day Time Temperature 0 C

Diesel Engine Oil: SAE Grade n/a 10W - 20 20W -20

Engine Radiator
Engine cooling system should have radiator preservatives added. Use antifreeze
conditioner if required.

Engine Diesel Fuel

If ambient temperature falls below +5ºC, a winter fuel or equivalent should be used to
prevent fuel waxing which can block the filter. Otherwise a fuel heating attachment is to
be considered.

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-19

5.4 General Rope Care

Recommended Storage and Handling of Ropes
When unreeling or uncoiling rope, AVOID the introduction of kinks or twists into the rope.
This type of damage is permanent and places weak spots in the rope. Mount the reel on
a vertical or horizontal axle and rotate the reel as the rope is pulled off.
When pulling rope out of a coil, the coil should be rolled on the ground to allow it to
uncoil. It should be treated the same as if it were being uncoiled from a spool.
Other points to note in the storage and handling of ropes include:
The stored rope shall be covered in a well ventilated area and away from
excessive heat. If covered storage is not available, the rope and reel shall be
covered with hemp material. This prevents humidity built up which would result in
corrosion of the rope.
For long periods of storage, apply a lubricant coating to the outside layer of the
rope on the reel, and cover the rope and reel with hemp material.
Care shall be taken during shipping and handling of the reel and rope to prevent
damage to the rope. The loose end of the rope on the reel shall be secured
properly to the reel. DO NOT drive a nail through the centre of the wire rope.

Fitting a New Rope

Limits must be reset when new ropes are fitted.

When anchoring a new rope on the drum, make sure that the entire cross section of the
rope is held solid; otherwise the inner strands may draw from the attachment, leaving
only the outer strands anchored. This can result in core protrusion.
The end of the rope should be brazed or tightly served to ensure no movement between
the inner and outer layers of strand can occur.
When winding the new rope on from a reel, always wind from the top of the reel to the top
of the drum or from the bottom of the reel to the bottom of the drum. Failure to do this will
put a reverse bend in the rope and shorten its life. Check with reeving diagram to ensure
correct winding. Following figure illustrates this concept.
The first layer on the drum must be wound on tight and true. Open or wavy winding will
cause serious damage to multiple layers.
Adjacent turns should be tapped against each other with a wooden mallet, when drum is
not grooved.
The whole rope should be wound on the drum tightly and correctly. A poor start will mean
poor winding and short life. Never allow ropes to become slack, always tension a rope
when onto the winch drum. Low tension can cause incorrect coiling on the drum which
may allow the rope slip between drum layers. If the rope has become slack, check the
coiling on the drum before continuing. The hoist requires 5 tonne of tension and the luff
requires 3 tonne.

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-20

REEL

DRUM

CORRECT METHOD

REEL

DRUM

INCORRECT METHOD

Figure 5.9 – Correct Spooling from Reel to Drum

Correct Reeving
Reeving of hoist or luff ropes must always conform to the reeving diagram.

After installing, run the rope through its operating cycle several times with
a light load and at reduced speed.

This will ensure that the new rope:

1) Adjusts itself gradually to working conditions,
2) Strands to become seated,
3) Some stretch to occur and
4) Diameter to reduce slightly as the strands and core are compacted.
By following the procedure above to condition the rope. A longer working life of the rope
can be achieved.

Always observe the first spooling onto the drum of a new rope.

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-21

Rope Inspection
All running ropes in continuous service should be visually inspected once every working
day. A thorough inspection of all ropes in use should be made at least once a month. Any
rope damage should be noted and the cause determined and fixed before loading the
rope.
No precise rules can be given to determine the exact time for replacements of ropes,
since many variable factors are involved. Safety in this respect depends largely upon the
use of good judgment by an appointed or authorised person. Conditions such as the
following should be sufficient reason for questioning rope safety and for consideration of
replacement.
Broken Wires
The following is guidance for the number of broken wires found in one (1) lay length.
1) Non rotation-resistant running ropes (such as those used in the main hoist fly
hoist and/or the luff) - six (6) randomly distributed broken wires within one (1)
lay length or three (3) broken wires in one strand within one (1) lay length.
2) Rotation-resistant ropes running ropes (such as those that may be used in the
main hoist.) - four (4) randomly distributed broken wires within one (1) lay
length or two (2) broken wires in one strand within one (1) lay length.
3) Standing ropes (such as boom pendants) - three (3) broken wires within one
(1) lay length or two (2) broken wires at the end connection.
Wire Rope Wear
Replace the rope if wear of more than one-third of the original diameter of the outside
wires of the strand has occurred.
Valley Break to Wire Rope
If one (1) valley break is observed, this may indicate internal rope damage requiring close
inspection of this section of the rope. When two (2) or more valley breaks are found in
one (1) lay length the rope should be discarded.

Figure 5.10 – Valley Break

Wire Rope Deterioration

Replace the rope if any kinking, crushing, bird-caging, or any other type of damage
results in the distortion of the rope construction.

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
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Heat Damage to Wire Rope

There is evidence of any heat damage from any source. Heat can be generated by
passing a rope over a frozen or non-turning sheave, contact with structural members of
the crane, improperly grounded welding leads or lightning strikes.
Wire Rope Diameter
Replacement of ropes should be considered where the difference in the rope diameter of
the lowest diameter of rope measured in three (3) working areas (areas where the rope
regularly goes over a sheave) compared to a non-working area (an area away from the
sheaves) is in excess of the values given in the table below
Maximum Reduction Maximum Reduction
Rope Nominal Diameter
(mm) (Inches)
Up to 19mm (3/4 inch) 1.19 3/64
20 – 30mm (7/8 to 1 inch) 1.59 1/16
31 – 39mm (1¼ to 1½ inch) 2.36 3/32

Figure 5.11 – Correct Method of Measuring Rope Diameters

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-23

Wire Rope Length

There is an observation of the increase in the length of an individual rope lay. This
increase in lay length and accompanying reduction in diameter can be caused by failure
of the core. This usually occurs more readily in ropes of rotation-resistant construction.
Wire Rope Corrosion
Extensive external and/or internal permanent corrosion is cause for rope replacement.
In the case of rotation resistant ropes which consist of a number of strand layers, internal
corrosion may not be readily detectable. During inspection, outer strands must be
separated to assess internal rope condition.
Wires in the rope which are corrosively pitted have greatly reduced flexibility and will
break much earlier as a result of rope bending over sheaves.
Rope Lubrication
A wire rope is made up of hundreds of wires which move relative to each other when the
rope runs over sheaves. When a rope is manufactured it is completely filled with
lubricant; firstly, to minimise frictional wear; and secondly, to keep out moisture and
resulting corrosion.
It is vital that this lubrication be preserved to get the maximum life from the rope. An
external coating of lubricant must be applied to the rope regularly to prevent the escape
of the internal lubricant and also reduce friction on the sheaves.
Lubricating the rope is as important as greasing any other part of the crane. Any of the
following methods can be used to lubricate the rope:
1) Pouring of lubricant onto rope as it passes over a sheave. Wipe off excess.
2) Swab the rope when not in motion with lubricant soaked rags.
3) Brush or spray with lubricant.
4) Pressure lubrication.
Tips to Maximise Rope Life
1) Never overload.
2) Do not shock load take up any slack carefully and apply the power smoothly and
steadily.
3) Protect ropes from sharp edges.
4) Avoid dragging ropes from under loads.
5) Avoid rolling loads with ropes.
6) Avoid dropping ropes from heights.
7) Never use rope that has been cut, kinked or crushed.
8) Prevent loops in slack lines from being pulled tight and kinking. A weak spot will
always remain no matter how well the kink seems to have straightened out. If a loop
forms do not pull it out, unfold it. Avoid reverse bends.
9) Never wind more that the proper amount of rope on to any drum.

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IOM – Section 5. Maintenance
5-24

10) Ensure that the rope ends are properly sized.

11) Ensure that the ropes do not bind in the sheaves.
12) Watch for local wear. Premature wear at one spot is common. Uneven wear can be
minimised by moving the rope so that different sections are at critical wear points.
The wear can be distributed by cutting a few meters of rope from the drum and re-
anchoring it.
13) Maintain the equipment over which the rope runs. Worn grooves, poor alignment of
sheaves and worn bearings can result in shock loads and excessive vibration.
Rope Defects

Mechanical damage due to rope

Localised wear due to abrasion on
movement over sharp edge whilst under
supporting structure
load

Narrow path of wear resulting in fatigue

Two parallel paths of broken wires
fractures, caused by working in a grossly
indicative of bending through an
oversized groove, or over small support
undersize groove in the sheave
rollers

Severe wear associated with high tread Severe wear in Langs Lay, caused by
pressure abrasion

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-25

Protrusion of rope centre resulting from

Severe corrosion
build up of turn

Typical wire fractures as a result of bend Wire fractures at the strand, or core
fatigue interface, as distinct from crown fractures

Break up of IWRC resulting from high Looped wire as a result of torsional

stress imbalance and/or shock loading

Typical example of localised wear and Multi strand rope bird caged to torsional
deformation imbalance

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
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Substantial wear and severe internal Internal corrosion whilst external surface
corrosion shows little evidence of deterioration

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-27

5.5 Service and Repair of Structural and Mechanical

Components
Gears and Gearboxes
Concentration should be given to preventive maintenance of gears and gearbox
components rather than complete overhaul, which requires highly specialised repair
equipment and skills. The gearboxes provided have a long life expectancy if lubricated
correctly.
Only competent mechanical technicians authorised by Favelle Favco should be used to
disassemble and reassemble gearboxes. Where problems occur within a gearbox or a
faulty gear, these should be serviced and repaired by a competent mechanical technician
provided by Favelle Favco Pty Ltd or by unit exchange of the complete gearbox.
Warranty may be voided, and the safe operation of the crane may be
compromised if gearboxes or gears have been tampered with or
dismantled and reassembled by unauthorised persons
The tampering, disassembly reassembly or modification of gearboxes or gears by any
person other than a competent mechanical technician authorised by Favelle Favco, may
make the crane unsafe and pose a risk of injury or death to persons, or damage to
property should such work cause a malfunction of the component or the crane to
malfunction.
It is therefore recommended that arrangements be made for the stocking of exchange
units.

Arc Welding
Due to the materials used and the forces imposed on the structural components of this
crane, repair or modifications, and in particular arc welding, should only be carried out in
accordance with FFC. recommended procedures. These are available on written request.
In the event that repairs or modifications to the steelwork above the
slew ring require electric arc welding, the earthing during the
activities MUST NOT BE VIA THE SLEWING RING.
Failure to observe this precaution could result in damage to the slew
ring.

Shaft and Pins

All shafts and pins are fabricated from high tensile steel and must never be replaced with
any material other than as specified by FFC.

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-28

Fasteners
Care should be exercised when replacing bolts or cap screws to ensure that the correct
thread and bolt grade is selected and the correct tightening torque is applied.
In general, metric thread fasteners are fitted, but other threads such as UNC and UNF
may be used on pumps and various other proprietary components.
Where grade and torque of a bolt is critical, the requirements are shown on the relevant
drawing.
The following is offered as a guide:
ISO Grade 8.8 bolts are used throughout the crane, for cover plates, brackets, handrails
etc., and other non primary structural components. Bolts less than 12mm are of stainless
steel type (SS316).
Grade 8.8 or 10.9 bolts are used mainly on winches, slew drives, slew ring, power pack,
slip ring assembly (if applicable), winch frame, bridle and mast.

Reinstatement of Coatings
Washing down to remove all grease and other foreign matter is essential before any
coating repairs are carried out.
If the top coats are mechanically damaged and require repair, feather back rough edges
and re-apply paint to the recommended thickness.
Refer to FFC. for paint specification to be used.
If damage has affected the primer, reprime and re-coat after spot blasting or mechanical
scrubbing to clean metal.

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 Pedestal Crane Model 20/10K, Serial N0. 1676
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5-29

5.6 Service and Repair of Fluid and Electrical Components

Hydraulic
Concentration should be given to preventive maintenance of hydraulic components rather
than complete overhaul, which requires highly specialised repair equipment and skills.
The wear rate of hydraulic pumps and motors is negligible as long as ample boost
pressure is provided and the oil is kept free from impurities and operated in a manner
that the temperature in the hydraulic circuit does not exceed 70ºC.
The hydraulic circuit contained in section 7 is provided solely for informational and
instructional purposes and is not to be used for adjusting hydraulic pressure settings.
Only competent hydraulic fitters authorised by Favelle Favco should be used to modify,
dismantle and reassemble components, or set hydraulic pressures etc. Where problems
occur within hydraulic components these should either be serviced and repaired by a
competent hydraulic fitter provided by Favelle Favco Cranes Pty Ltd or by unit exchange
of the complete hydraulic component.
Warranty may be VOIDED, and the safe operation of the crane may be compromised if
hydraulic components have been tampered with or dismantled and reassembled by
unauthorised persons.
Before removing any unit from the installation, clean areas adjacent
to ports and drains. Remove pipes or hoses and cover these and
component ports to prevent the ingress of dirt.

Pressure Override on Variable Displacement Motor

Control Description: Motors fitted with option allow remote control of the motor
displacement until system pressure reaches the pressure setting of the pressure override
(POR) valve. When this occurs, displacement adjusts automatically towards maximum,
until the product of displacement and set (system) pressure satisfies the output torque
demand put on the motor.
System pressure greater than the set pressure of the POR valve will keep the motor at
maximum displacement, even if the HD, EP, or EZ control signal is set to send the motor
to minimum displacement.
The integral POR valve has the capability of a high low pressure setting. This allows the
system pressure at which the override functions to be preset at two different pressure
levels.
High range is selected by supplying a pressure signal from “G” port to the “G2” port of the
POR valve. Adjustment screw “A” is used to set the high POR setting.
Low range is selected by blocking the pressure supply from the “G” port and connecting
the “G2” port of the POR to tank. Adjustment screw “B” is used for the low POR setting.
If a single POR setting is required for an application, adjustment screw “B” should be
turned in (clockwise) until firm resistance is encountered; ports “G2” and “G” are plugged.
Adjustment screw “A” is then used to set the override pressure or pressure setting, refer
to the hydraulic circuit relevant to this crane.

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 5. Maintenance
5-30

Electric
Electrical components within this crane are serviceable by a competent electrician, the
exception being any electronic items.
As previously mentioned, it is recommended to have exchange units for the most
important parts stocked for fast replacement.
All sources of electricity supply to the boom must be shut off before
any piece of electrical apparatus is serviced.

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 6 TROUBLESHOOTING
GUIDELINE
6.1 General Trouble Shooting List ............................................................... 6 2

6.2 Planetary Drives.................................................................................... 6 7

6.3 Ropes.................................................................................................... 6 9
 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 6. Troubleshooting Guideline
62

6.1 General Trouble Shooting List

The following table will be very useful for finding and solving causes of break-downs
and common problems that occur during crane operation. Needless to say this list is
not exhaustive, as it is impossible to set down all the causes and their associated
solutions.

No (or Very Low) Boost Pressure [Engine Should Cut Out]

PROBABLE CAUSE REMEDY
Faulty pressure gauge Replace
Damaged/blocked boost pump
Stop immediately - call FFC
suction hose(s)
Damaged drive coupling /between
Stop immediately - call FFC (replace)
engine and gearbox
Check reason. Boost pressure relief valve
Boost pressure setting too low
should match circuit. Consult FFC
(Faulty) anti-cavitation switch or
Adjust or replace as necessary
setting incorrect

No Motions (With Engine Running)

PROBABLE CAUSE REMEDY
Lines between cabin & winch frame
Check lines. If in doubt, consult FFC
connected incorrectly gauge
No boost pressure (or very low boost
Stop immediately. Refer above.
pressure)
Reset or replace as necessary - Consult
Limits are tripped or malfunctioning
FFC
Cabin control levers not functioning
Replace levers
correctly
(Faulty) anti-cavitation switch or
Adjust or replace as necessary
setting incorrect
Faulty relay Check wiring
Check solenoid and spool movement.
Faulty/jammed main oil solenoid
Repair/replace as necessary

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No Hoist Up (Other Motions OK)

PROBABLE CAUSE REMEDY
Hoist winch is overloaded Reduce load to comply with load chart
Recalibration necessary. Temporary
S.L.I. not calibrated correctly -
bypass may be done only by qualified
showing overload
personnel
Check brake valve & check cabin control
Brake not releasing
lever functioning
Qualified personnel can adjust. Check
Pump relief valves set incorrectly
reason
Pump controller not functioning Replace controller. Qualified personnel to
correctly inspect/repair
Emergency lowering bypass valve
Close or replace
open or leaking
Winch drives damaged Consult FFC
Qualified personnel can bypass or reset as
Hoist up limit is tripped
necessary if at top hoist down
Leakage or block in hoist up control
Fix leak or replace hose as necessary
line from lever
No Hoist Down (Other Motions OK)
PROBABLE CAUSE REMEDY
Qualified personnel can bypass or reset as
Hoist down limit is tripped
necessary
Check brake valve & check cabin control
Brake not releasing
lever functioning
Pump controller not functioning Replace controller. Qualified personnel to
correctly inspect/repair
Leakage or block in hoist down
Fix leak or replace hose as necessary
control line from lever
Loaded Hook Drops Slightly Before Lifting
PROBABLE CAUSE REMEDY
Brake releasing too early Qualified personnel to adjust
Pump not correctly in neutral Qualified personnel to adjust
Excessive leakage in pump or motor Consult FFC

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64

Empty Hook (or Light Load) Initially Jumps Up When Hoisting

PROBABLE CAUSE REMEDY
Brake releasing too late Qualified personnel to adjust
Pump not correctly in neutral Qualified personnel to adjust
No Luff Up (Other Motions OK)
PROBABLE CAUSE REMEDY
Qualified personnel can bypass or reset as
Luff up limit tripped
necessary
Luff in deceleration valve tripped or
Qualified personnel to adjust and check
malfunctioning
Luff ratchet not releasing Check cylinder
Luff winch is overloaded Reduce load to comply with load chart
Check brake valve & check cabin control
Brake not releasing
lever functioning
Qualified personnel can adjust - check
Pump relief valves set incorrectly
reason
Pump controller not functioning Replace controller. Qualified personnel to
correctly inspect/repair
Winch drives damaged Consult FFC
Leakage or block in luff control line
Fix leak or replace hose as necessary
from lever
Luff Ratchet Not Releasing
PROBABLE CAUSE REMEDY
Brake valve shuttle (if applicable)
Replace if necessary
problem
Luff ratchet solenoid (if applicable) Replace coil or valve as necessary - fault
problem trace if signal not coil
Ratchet cylinder not functioning
Check cylinder
properly
Brake valve release pressure set Qualified personnel can adjust as
incorrectly (if applicable) necessary. Check reason
Damaged / leaking cylinder line Replace/repair if as required

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 Pedestal Crane Model 20/10K, Serial N0. 1676
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No Luff Down (Other Motions OK)

PROBABLE CAUSE REMEDY
Qualified personnel can bypass or reset as
Luff down limit is tripped
necessary
Motion cut activated on S.L.I. due to Check load against S.W.L. luff up or hoist
overload down only permissible
Recalibrate if necessary. Temporary
S.L.I. not calibrated correctly -
bypass may be done only by qualified
showing overload
personnel
Qualified personnel can adjust as
Luff ratchet not releasing
necessary. Check reason
Check brake valve - check cabin control
Brake not releasing
lever functioning
Pump controller not functioning Replace controller. Qualified personnel to
correctly inspect/repair
Leakage or block in luff down control
Fix leak or replace hose as necessary
line from lever

Crane Will Not Slew (Other Motions OK)

PROBABLE CAUSE REMEDY
Slew brake is on Move slew brake lever to ’off’ position
Slew in opposite direction. Qualified
Slew limit is tripped (if fitted) personnel. can bypass or reset as
necessary
Brake not releasing Check brake valve in cabin
Pump controller not functioning Replace controller Qualified personnel. to
correctly inspect/repair
Cabin control lever not functioning Replace lever. Qualified personnel to
correctly inspect/repair
Slew drive damaged Consult FFC
Qualified personnel. can adjust - check
Pump relief valves set incorrectly
reason

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Engine Will Not Start

PROBABLE CAUSE REMEDY
Check correct voltage from electric circuit.
Batteries are flat
Charge or replace as necessary
No diesel fuel Check level and fill as required
Fuel filters or air cleaner is blocked Check and replace as required
Check starter motor and pinion. Replace as
Starter motor damaged
required
Hydraulic oil is too thick (especially in
Replace with lower viscosity oil
cold climate)
Fuel is contaminated (eg. water) or
Check fuel, filters and water separator
waxed (i.e. incorrect fuel for cold
(where applicable)
climate)
Check limits. Qualified personnel can
Ultimate limit(s) tripped
bypass if necessary

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6.2 Planetary Drives

With Motor Running the Shaft Output Doesn’t Turn
PROBABLE CAUSE REMEDY
Check coupling between gear unit and
Incorrect motor assembly
motor
Internal malfunction Contact FFC or service Centre
Brake blocked Check hydraulic circuit
Oil Leak From Breather During Operation
PROBABLE CAUSE REMEDY
Level too high Lower oil level
Incorrect breather position Check breather position
Possible wear of multi disk seals or
Contact FFC or service Centre
hydraulic motor
Oil Leak from Seal
PROBABLE CAUSE REMEDY
Clogging breather plug Unscrew and thoroughly clean the plug
Stiffening of seals due to prolonged Clean the area and check for leakage
storage again after a few days
Damaged or worn seals Contact FFC or service Centre
Excessive Noise
PROBABLE CAUSE REMEDY
Internal malfunctions Contact FFC or service Centre
Disk Brake Does Not Release
PROBABLE CAUSE REMEDY
Residual pressure in hydraulic circuit Check hydraulic circuit
Excessive Vibrations
PROBABLE CAUSE REMEDY
Check the connection and inline
Gear unit incorrectly installed
configuration
Internal malfunction Contact FFC or service Centre

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Excessive Heating
PROBABLE CAUSE REMEDY
No ventilation Contact FFC or service Centre
High thermal pressure Insert oil circulation
Multi Disk Brake Does Not Release
PROBABLE CAUSE REMEDY
No pressure to the brake Check connections to hydraulic circuit
Internal malfunction Contact FFC or service Centre
No pressure in the circuit Check hydraulic circuit
Multi Disk Brake Does Not Brake
PROBABLE CAUSE REMEDY
Pressure delivered to brake Check hydraulic circuit
Worn disks Contact FFC or service Centre
Disk Brake Does Not Brake
PROBABLE CAUSE REMEDY
No pressure to the brake Check hydraulic circuit
Worn brake Pads Replace brake pads

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6.3 Ropes
Mechanical Damaged Caused by the Rope
Description Causes/Actions
Mechanical damaged caused by the Generally results from operational
rope contacting the structure of the conditions
crane on which it is operating or an Check sheave guards and supports/guides
external structure – usually of a sheave to ensure that the rope has not
localised nature. jumped out of the intended reeving system
Review operating conditions
Strand Separation
Description Causes/Actions
Check sheave and drum groove radii using
sheave gauge to ensure that they are no
smaller than nominal rope radius +5%
Repair or replace drum/ sheaves
Check feet angles in the reeving system
Opening of strands in rotation
resistant, low rotation and parallel Check installation method – turn induced
closed ropes – in extreme during installation causes excessive rope
circumstances the rope may develop rotation resulting in distortion
a birdcage distortion or protrusion of Check if the rope has been cut on site prior
inner strands to installation or cut to remove a damaged
section. If so, was the correct cutting
method used. Incorrect cutting of rotation
resistant, low rotation and parallel closed
ropes can cause distortion in operation
Rope may have experienced a shock load
Problems at Rope Crossover Points
Description Causes/Actions
Check tension on underlying layers
Broken wires or crushed or flattened Review wire rope construction
rope on lower layers at crossover Do not used more than necessary
points in multi-layer coiling situations. Check drum diameter. Insufficient bending
ratio increases tread pressure

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 Pedestal Crane Model 20/10K, Serial N0. 1676
IOM – Section 6. Troubleshooting Guideline
6 10

Wire Looping From Strands

Description Causes/Actions
Insufficient service dressing
Consider alternative rope construction
If wires are looping out of the rope
Wire looping from strands underneath a crossover point, there may
be insufficient tension on the lower wraps
on the drum
Check areas for rope crushing or distortion
Pigtail or Severe Spiralling in Rope
Description Causes/Actions
Check that the sheave and drum diameter
is large enough
Pigtail or severe spiralling in rope May indicates that the rope has run over a
small radius or sharp edge
Check to see if the rope has jumped off a
sheave and has over a shaft
Two Lines of Broken Wires Running Along the Rope
Description Causes/Actions
Two single axial lines of broken wires Check sheave and drum groove radii using
running along the length of the rope sheave gauge to ensure that they are no
approximately 120 degrees apart smaller than nominal rope radius +5%
indicating that the rope is being Repair or replace drum/ sheave if
nipped in a tight sheave necessary
One Line of Broken Wires Running Along the Rope
Description Causes/Actions
Check to see if the groove diameter is no
One line of broken wires running greater than 15% the nominal rope
along the length of the rope diameter
indicating insufficient support for the
Repair or replace drum/sheaves is
rope, generally caused by oversize
necessary
sheave or drum grooving
Check for contact damage

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Shortened Rope Life (Even Wear)

Description Causes/Actions
Fatigue induced wire breaks are
characterised by flats ends on the broken
wires.
Bending fatigue is accelerated as the load
Short rope life resulting from increases and as the bending radius
evenly/randomly distributed bend decreases. Consider improving the ratio
fatigue wire breaks caused by
Check fleet angle to drum
bending through the reeving system.
Check general alignment of sheaves in the
reeving system
Check that all sheaves are a free to rotate
Check wire rope construction
Review rope selection
Shortened Rope Life (Localised Wear)
Description Causes/Actions
Fatigue induced wire breaks are
characterised by flats ends on the broken
wires
Bending fatigue is accelerated as the load
increases and as the bending radius
Short rope life resulting from decreases. Consider improving the ratio
localised bend fatigue wire breaks. Check wire rope construction
Localised fatigue breaks indicate
continuous repetitive bends over a short
length. Consider whether it is economic to
periodically shorten the rope in order to
move the rope to the system and
progressively expose fresh rope to severe
bending zone

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Broken Rope
Description Causes/Actions
Corrosion of rope both internally or
externally can also result in a significant
loss in metallic area. The rope strength is
Ropes are likely to break when
reduced to a level where it is unable to
subjected to substantial overload or
sustain the normal working load
misuse
More likely to occur when a rope has
already been subjected to mechanical
damage
Review operating condition
Wave or Corkscrew Deformations
Description Causes/Actions
Check sheave and drum radii using sheave
gauge to ensure that they are no smaller
than nominal rope radius +5%
Normally associated with multi- Repair drum or sheaves
strand ropes Check fleet angles in the reeving system
Check the rope has been secured in
accordance with manufactures instructions
Check operating conditions for induced turn
Rotation of the Load in a Single Fall System
Description Causes/Actions
Review rope selection
Load spinning when hoisting or
lowering Consider use of rotation resistant or low
rotation rope
Rotation of the Load in a Multi Fall System
Description Causes/Actions
Review rope selection
Review installation procedure or operating
procedures
Resulting in cabling of the rope Possibly due to induced turn installation or
operation
Consider use of rotation resistant or low
rotation rope

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6 13

Core Protrusion or Broken Cores

Description Causes/Actions
Occurs in a single layer six or eight Caused by repetitive shock loading –
strand rope review operating conditions
Rope Accumulating or Stacking at Drum Flange
Description Causes/Actions
Rope accumulating or stacking at Review drum design with original
drum flange due to insufficient fleet equipment manufacturer – consider adding
angle rope kicker, fleeting sheave
Sunken Wraps of Rope
Description Causes/Actions
Check correct rope diameter
Sunken wraps of rope on the drum If grooved drum check groove pitch
normally associated with insufficient Check tension on underlying layers
support from lower layers of rope or Make sure that the correct rope length is
grooving being used. Too much rope may aggravate
the problem
External Corrosion
Description Causes/Actions
Consider selection of galvanised rope
External corrosion
Review level and type of service dressing
Internal Corrosion
Description Causes/Actions
Consider selection of galvanised rope
Consider selection plastic impregnated wire
External corrosion
rope
Review level and type of service dressing

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