CRANE MAINTENANCE MANUAL

（electric）

FOR
SIX RUBER TYRED GANTRY CRANES
FOR SPBUN TERMINAL AT BUENAVENTURA

Doc ID: D22-022A-MNT

(1002000077)

Shanghai Zhenhua Heavy Industries Co., Ltd.

June 1, 2018
 Crane Maintenance Manual

Safety Symbol Legend

Indicates a procedure, practice, condition,

or statement that, if not strictly observed,

could result in personal injury or death.

Indicates a procedure, practice, condition,

or statement that, if not strictly observed,

could result in damage to or destruction

of equipment.

Indicates an essential or important

procedure, practice, condition, or statement.

We reserve all rights in this document and in the information contained herein.
Reproduction, use of disclosure to third party without express authority is strictly
forbidden.

(C) ZPMC, Shanghai Zhenhua Port Machinery Co., LTD.

 Crane Maintenance Manual

Table of Content
I. About This Manual ..................................................................................................................................... 1
II. Crane basic situation introduction ........................................................................................................... 3
III. Maintenance Stations ............................................................................................................................ 5
IV. Transformer ............................................................................................................................................. 8
V. Three-phase AC motor ............................................................................................................................ 12
VI. Special cables ....................................................................................................................................... 17
VII. Air-condition .......................................................................................................................................... 18
VIII. LV Cabinet ............................................................................................................................................. 22
IX. Slipping Box <Just for cable reel system RTG > ............................................................................. 24
X. Cam Limit Switch.........................................................................................................错误!未定义书签。
XI. Load Cell Sensor .................................................................................................................................. 27
XII. Outdoor Monitoring Equipment .......................................................................................................... 28
 Crane Maintenance Manual

I. About This Manual

This manual is compiled the maintenance requirements of 41 tons rubber tyred gantry
cranes that are designed and built by Shanghai Zhenhua Port Machinery Co., Ltd.
(ZPMC) for SPBUN Terminal at BUENAVENTURA.
This manual covers the basic maintenance requirements of the crane. When
equipments/components’ manufacturer has its own maintenance requirement, it should
be followed at first. If further information is desired or if particular problems arise that
are not covered sufficiently for the purchaser’s purpose, the matter should be referred to
ZPMC.

This document contains proprietary information of ZPMC and is furnished to its customer
solely to assist that customer in the maintenance of the equipment described. ZPMC
retains all intellectual property and other rights in or to the information contained herein,
and such information may only be used in connection with the maintenance of your
cranes. This document shall not be reproduced in whole or in part nor shall its contents
be disclosed to any third party without the written approval of ZPMC.

1. This manual includes the maintenance requirements of the crane. It doesn’t

include the crane operation.

2. This manual is very important for the other maintenance personnel. Please
put this book back to original position after your reading!

3. This manual describes the daily maintenance requirement. When

equipments/components’ manufacturer has its own maintenance requirement,
it should be followed at first.

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 Crane Maintenance Manual

Safety first
1. Carefully read and understand this manual and relative equipment’s
manuals first, before doing any maintenance. These requirements
should be followed during whole service activities.

2. Always following the safety regulations/rules/requirements issued by

the government and enterprise.

3. Only qualified technician can do the maintenance.

4. Switch off the power before doing maintenance. Make sure nobody
else can turn on the power.

5. Wear hard hat before enter in crane. Wear safety belt when working
on non-normal passage-way or non-normal maintenance area. Wear
corresponding protection device when doing special maintenance
activities.

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 Crane Maintenance Manual

II. Crane basic situation introduction

1. Main parameter and performance index

1.1 Type of crane Ruber tyred gantry crane

1.2 Rated Load

Single container <41> Tons (under spreader)
1.3 Type of spreader <20’, 40’, > spreader
1.4 Rail span <23.47>m

1.5 Trolley

Total trolley travelling length <18.5>m

1.6 Hoist height

Total Hoist height <21>m

1.7 Main electric power class

Drive incoming power <460>VAC, 3 phase , <60> Hz
3ph auxiliary power <208>VAC, 3 phase , <60> Hz
<460>VAC, 3 phase , <60> Hz
Lighting/outlet power <120>VAC, 1 phase , <60> Hz
Control power <120>VAC, 1 phase, <60>Hz
<24>VDC
HV incoming power from PCR <0.9> kV, 3phase, <60> Hz

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 Crane Maintenance Manual

General crane drawing

2. Rated speed

2.1 Main hoist speed

(rated load) hoisting speed <30> m/min

(rated load) lowering speed <30> m/min

(empty load) hoisting speed <60> m/min

(empty load) lowering speed <60> m/min

2.2 Trolley speed <70 m/min

2.3 Gantry speed

(rated load) gantry speed <70> m/min

(empty load) gantry speed <135> m/min

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 Crane Maintenance Manual

III. Maintenance Stations

There are some station can be operated by the maintenance people only. Please find
the description in following chapters.

1. Wheel Turning Control Station

This station can be operated by the maintenance people only.

Wheel turning control station Picture

The control model of “LOCAL/AUTO” selector can be changed in the e-room.
When the selector is selected to “AUTO” position, then the operator can operate the wheel
turning in the cabin by the pushbuttons or selectors on the console, and the wheel turning status
indicators can be shown accordingly.
When the selector is selected to “Local” position, then the maintenance staff can fulfill the
function by the pushbuttons or selectors on the wheel turning control box under the both of sill beam .

1. Only the maintenance staff can operate the wheel turning by wheel turning
control box.
2. When manual operate the wheel turning .there are at least two maintenance
staffs on site. And one person to operate the pushbuttons or selectors, and
another one to observe the turning status to avoid any accident.

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 Crane Maintenance Manual

The operation process of the both control station is the same. The steps is as below :
To 90DEG：
Control on  local mode  Turn Permit on 1#/2# (or 3#/4#) 90 pushbutton  wheel to
90deg  Turn Permit off
To 0DEG：
Control on  local mode  Turn Permit on 1#/2# (or 3#/4#) 0 pushbutton  wheel to 0
deg  Turn Permit off
To parking position：
Control on  local mode  Turn Permit on  2#,4# 90 pushbutton 2＃、4＃wheel to 90
deg Turn Permit off
Note：to keep the function well, each station should be operated by nonscheduled.

2. Cable Reel Local Control Station

Cabel reel local control station picture

1. “Modo Manual Activado”Key Switch

2. “En-Rollado Manual”push button
Components
3. “Desen-Rallado Manual”Push Button
and location
4. “Re-Iniciar”Push Button
5. “Para De Emergencia”Push Button
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 Crane Maintenance Manual

1. When the HV cable is loose or tighten too much, the

maintenance staff can manual operate the local control station
to adjust it
2. Turn the “Modo Manual Activado Key switch” to “ ON “position.
3. According the actual conditions to operate “En-Rollado Manual”
or “Desen-Rallado Manual” pushbutton
Function
4. Turn the “Modo Manual Activado Key switch” to “ OFF “position.
5. When there’s fault occur, Push the “Re-Iniciar” pushbutton to
reset fault ,and then you can manual operate the related
functions
6. When there’s fault emergency condition occur, Push the “Para
De Emergencia” pushbutton to Stop the Power cable reel

Note：Each station should be operated aperiodically ,to make sure the functions are
well!

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 Crane Maintenance Manual

IV. Transformer

1. Strictly following the relative electrical power operation safety

rules. The transformer is operated only by qualified people with

guardian on site.

2. Before any maintenance, fully discharge both MV side and LV

side. Separate the transformer from the incoming and outgoing.

Grounding all transformer terminals.

This chapter does not cover all kinds of the transformers. The

maintenance manual from the transformer manufacturer should be

followed at first.

1 Technical Data：

Main transformer Auxiliary transformer

Rated Power 400 50 KVA

Rated Frequency 60 60 Hz

Input Voltage 900 460 V

Output Voltage 460 208 V

2 In order to keep transformer running in good status and prolong its service lift, it is
important to do the transformer maintenance periodically. The maintenance period
is depending on the external factors, such as the environment, etc.
2.1 First maintenance service can be done one month after transformer is
energized.
2.2 In dry and clean environment, the maintenance can be done every year.
2.3 In dusty and chemical fog environment, the maintenance can be done every
3-6 months.

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 Crane Maintenance Manual

2.4 In heavily polluted environment, the maintenance should be done every month.
3 The periodic inspection includes following items:

Do not power on the transformer if there is any condensate

water on the transformer.

3.1 Check every fastening device of the transformer. Fasten it when needed.
3.2 Check all connection points in the power-circuit, any loose will cause
overheating on the connection. Check if there is any stain, rust on the electric
and other parts or not.
3.3 Check if accessories’ circuits are normal or not.
3.4 Check the grounding of transformer itself and covers.
3.5 Check the transformer winding resin for cracks, electric corrosion or
carbonization. If any damage is found, please contact the transformers’
manufacturer.
3.6 Measure the insulation resistance and record the value.
4 Periodic cleaning, especially the surface cleaning, is very important to maintain the
transformer in good cooling and insulation level. The cleaning should be done as
following:
4.1 Do a comprehensive visual inspection for coils, leads and the temperature
monitor.
4.2 Check if there is any foreign substance inside or outside of the transformer.
Remove it if anything found.
4.3 Clean the insulators, leads, insulating spacers and windings. The dust removal
can be done by vacuum cleaner or air compressed with dry air/nitrogen. The
compressed air/nitrogen should be no more than 0.2 MPA. The surface of the
insulators, wires, terminal plates and other insulated parts should be cleaned
by dry cloth.
4.4 Do the maintenance on accessory device according the relative manual.
5 The preventive test is suggested to be done every three years. It should be done
immediately if any fault happens. The test includes voltage withstands, transformer
ratio error check and percent impedance etc.
6 One month after transformer is in operation, check the fastening torque of every
bolts according the suggested value in following table:

Bolt Size (mm) M8 M10 M12

Torque (N. m) 21 30 50

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 Crane Maintenance Manual

7 Appendix:

Typical Faults and Solutions:

Faults Possible Cause Solutions

Winding is wet or with dust on the
Insulation too Remove the dust with dry air
surface
low
Aging insulation Contact the manufacturer
MV side voltage MV side voltage too high or too Check installation and contact
abnormal low the MV power supplier
MV side voltage too high or too Check installation and contact
low the MV power supplier
Wrong tapping connection on MV
Change tapping connection
LV side voltage side
abnormal Loose tapping connection on MV
Tighten tapping connection
side
Winding not continuous Contact the manufacturer
PT or voltmeter abnormal Replace with a new one
Wrong tapping connection on one
Change tapping connection
phase
One of the fuse on MV side
Replace with a new one
Three phase damaged
unbalance Change load arrangement and
Load unbalance
balance it
Connecting bolts loose Check installation and tighten
PT or voltmeter abnormal Replace with a new one
Thermal protection setting
Change setting
incorrect
Upper steam Thermal protection malfunction Replace it with a new one
protection Temperature sensor malfunction Replace it with a new one
tripped when Wrong type of fuse or protective Check the actuation time and
working or relay current
putting in Overload Check the load
operation Winding insulation damaged Contact the manufacturer
Check the polarity and
Wrong CT wiring
connections
Continuous overload Contact the manufacturer
Dust or fouling on winding Contact the manufacturer
Insulation
Mechanical damage during
damaged or Contact the manufacturer
transportation or installation
Smoky
Lighting rod or surge absorber
Contact the manufacturer
damaged
Temperature Continuous overload Contact the manufacturer
abnormal Bad Ventilation Improve ventilation
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 Crane Maintenance Manual

Faults Possible Cause Solutions

Environmental temperature too
Cooling by air-condition or fan
high
Iron core abnormal overheating
caused by under frequency on Check the MV side connection
MV side over voltage
MV side under frequency or over
Check the MV side connection
voltage
Vibration and Framework loose during the
Tighten it
noise transportation or installation.
Reflection voice caused by too
Remove obstacle
close to the wall or other things
Overload Check the load
Transformer Under frequency Check the frequency
under efficiency MV side over voltage Check MV side voltage
Wrong tapping connection Check tap connection
Terminal
Wrong bolt connection Tighten it
overheating
Note: Not all type of transformers will have above mentioned parts

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 Crane Maintenance Manual

V. Three-phase AC motor

1. Before any maintenance, make sure all motor circuits have been
turned off. Don’t forget turn off the accessories’ circuits, such as

heaters.

2. Some parts will be high temperature after running.

This chapter does not cover all kinds of the motors. The maintenance

manual from the motor manufacturer should be followed at first.

1 If the crane is out of operation for long time, the following measures should be done:
1.1 Measure the winding resistor and temperature every three months.
1.2 Check the status of motor painting every three months. Repainting if
corrosion happened.
1.3 Check the protection of motor metal no-painting surface. Any corrosion found,
clean it with sand paper and finish it with anti-corrosion measure.
1.4 Check the rotor balance status if time duration is longer than one year.
1.5 Redo the motor no-load test if time duration is longer than one year.
1.6 Turn the motor at least 10 turns every three months to keep the bearing at good
status.
1.7 Keep the motor heater working.
2 If the motor is just repaired, or putting into service for 1000 hours or 1 year
(whichever comes first), the following inspection should be done:
2.1 When motor is running, check if the electrical and mechanical characteristics
are qualified or not. For example, check if there is any excessive current.
2.2 When motor is running, check the smell, vibration, and noise. Burning smell
can be caused by overheated winding; while vibrations and noises can be
caused by some mechanical faults. If any burning smell or abnormal vibration
or noise found, please turn off the motor immediately.
2.3 When motor is running, check the bearing temperature and oil leakage.
2.4 When motor is not running, check if there is any crack on the motor or not.
2.5 When motor is not running, check the motor inside. Motor internals should be
away from water dripping, oil and foreign substances. Air inlet and outlet
should be unobstructed. Drain holes, if exist, should be unblocked.
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 Crane Maintenance Manual

2.6 When motor is not running, check if the motor installation is still OK or not.
2.7 When motor is not running, check coupling and installation bolts. Make sure
there is no discoloration of the cables and insulation parts.
2.8 When motor is not running, check if the winding insulation is good enough or
not.
2.9 When motor is not running, make sure the insulated bearing, if adopted, is not
bypassed.
3 Motor lubrication and lubrication grease
3.1 The type of lubricating grease and the lubricating interval should follow the
motor manual or nameplate. Normally, the minimum temperature for general
lubricating grease operable is -20° C.
3.2 The following lubricating interval is only considering for horizontal installed
motor whose working temperature is no less than 40° C. This lubricating
interval should be shortened when it is variable frequency motor, or vertical
installed motor, or the high speed running motor, or motor mounted in vibrating
place, with impact load, or frequently forward/backward running motor.
3.3 If different brands lubricating grease is used, this lubricating interval should be
shortened.
3.4 When it is permanent greased 4-pole motors, the lubricating interval is
20000-40000 hours. When it is permanent 2-pole or 2/4 poles motors, the
lubricating interval is 10000-20000 hours. The above lubricating intervals
should be shortened as for the big motor.
3.5 When it has grease nipple for the motor bearing, the maximum lubricating
interval is 12 months.
4 The motor filter needs regularly cleaning and replacement. Excessive dust on the
filter will block the air getting into the motor and cause the motor overheating. The
filter can be cleaned as the following:
4.1 Loose the fastening bolt and take out the filter together with its frame. When
cleaning the filter, never crumple or twist it.
4.2 Clean the filter by warm water.
4.3 If there is oil on the filter, dip the filter into cleanser for about 10 minutes before
cleaning.
4.4 After the filter is dry, clean it by compressed air.
4.5 Clean the floating dust on the filter by vacuum cleaners.
4.6 Install the filter back in right direction.
4.7 If any hole or fiber broken found, the filter needs to be replaced.
5 Every inspection must be recorded and signed.
6 Appendix:

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 Crane Maintenance Manual

Typical Faults and Solutions

Faults Possible Cause Solutions

Check the stator winding, fix the open
Stator phase open
phase.
Short circuit between Check if the resistance and the non-load
circuits or phases on the current of each phase is balance or not.
stator Find the short circuit and fix it.
Unable to Correct the stator winding wiring
Wrong connection on
start according the wiring diagram on the
stator
nameplate.
Overload or gearing Separate the motor from the load, if the
mechanical fault motor is able to start, check the gearing.
Drive parameter setting Check the drive parameter and make
wrong adjustment.
Wrong parameter setting
Speed Reset the parameter according to the
of output voltage and
lower than requirements
frequency
rated
Load too heavy Check the gearing
Mechanical friction Check the air gap between stator and
(between stator and rotor) rotor, find out the reason and fix it.
Run the motor again, if it is unable to
Phase lose running restart, one phase may lose, check the
power supply and the motor to fix it.
Bearing lack of grease or Clean the bearing and lubricate it, or
Abnormal damaged replace with a new one.
noise or Motor wiring wrong Find out and fix it
vibration Rotor unbalanced after
Make it balanced
repair
Make it straight or replace with a new
Motor shaft distorted
one if needed
Coupling loose Find the loose bolt and tighten
Installation base not Check the installation base and make it
horizontal or with flaw horizontal
Check the current on drive panel display
or measure the stator current by
Over load
electromagnetic ammeter. If overload
found, please reduce the load.
Motor
Check the wiring of the drive and the
overheating Phase-lose running
motor. Fix it when needed.
Mistake Y connection for △ connection,
Motor connection wrong or mistake △ connection for Y
connection. Turn off the power and

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 Crane Maintenance Manual

Faults Possible Cause Solutions

change the connection ASAP.
Stator winding Find the grounding or short-circuit part
short-circuit and fix it.
Squirrel-cage rotor
Replace it with a new one, if needed
broken
Check if the bearing, stator and rotor are
Friction between stator
in good installation level or not. Fix if it is
and rotor
not good.
Check if the fan is damaged, or the air
duct is blocked. Repair the fan if
Poor ventilation damaged. Remove the obstructions
and clean the duct to make good
ventilation.
Motor over-excitation
when running in low
Adjust the U/f parameter setting
speed caused by wrong
U/f parameter setting
Adjust the braking current setting
Braking current too high
according to the braking frequency.
when using inverter’s DC
Generally the setting is 100%-150% of
braking function
rated current.
Bearing damaged Replace with a new one
Bearing grease too much
Adjust or replace the grease
or too less or impure.
Assembly between
bearing and axis, bearing
Fit it
Bearing and cover too loose or too
over tight
heating Poor installation of motor
Make it fit and tighten the bolt
or bearing cover
Poor installation of the oil
Adjust the installation
seal for IP54 motor
Poor installation of belt or
Adjust the installation
coupling

Bad grounding Check the grounding of the motor casing

Winding vapored or
Dry it
Motor insulation too low
casing Stator winding insulation
Repair the motor
electrified too low
Dirty terminal board Clean it.
Out-lead insulating wears
Wrap it with insulation material.
out
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 Crane Maintenance Manual

Note: Not all type of motors will have above mentioned parts.

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 Crane Maintenance Manual

VI. Special cables

Some special cables need periodic inspection. The inspection is carried out
visually at least once a year.

Attached, please find some examples：

Cable Type Appearance Solution

Cable for spreader RHEYCORD
Spiral cable
basket (BS)
Festoon cable CHAINFLEX Cracked cable

Crinkly cable 联系供货商

RHEYCORD
HV cable Spiral cable
(RTS)
Cracked cable

Attached, please find the pictures of these examples:

Spiral cable

Cracked cable

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 Crane Maintenance Manual

VII. Air-condition

Before any maintenance, make sure all air-condition’s power circuits

have been turned off.

This chapter does not cover all kinds of air-conditions. The maintenance

manual from the air-condition manufacturer should be followed at first.

In order to keep air-condition running in good status and prolong its service life, it is
important to do the air-condition maintenance periodically. As for air-condition on board
the cranes, the maintenance can be done as the following.
1 Monthly maintenance items
1.1 Clean air-condition filter
 Air-condition filter is usually installed at return air port according to the
environment. It can effectively filter dust, pollen and other impurities, etc in
the air in order to protect the evaporator.
 Air-condition filter is usually made of textile fiber or leno. If it is not cleaned
timely, the air volume will get lower and the cooling effect gets worse.
 To clean the filter, the service people can put it on a hard even place, and
flap it gently to remove the big impurities. Washed it by warm water with
neutral cleanser if needed. Install it back until dried.
 If any hole or fiber broken found, the filter needs to be replaced.
1.2 Check rubber belt (only for indoor unit with belt driven)
 If the rubber belt is under tension, the friction between the belt and the belt
pulley will be too small to drive fan to rotate, which will cause the air volume
and residual pressure getting insufficient and the cooling effect getting worse.
However, if the rubber belt is over tension, the bearing and axis of the fan
motor will become easy to wear out, which will reduces the fan’s service life.
Either the rubber belt too loose or too tight will be harmful to the fan system
and increase noise.
 One week after air-condition is in operation, readjust the belt tension properly.
Later on, please do periodic inspection every month. Adjust the rubber belt
or replace it if needed.
1.3 Condenser cleaning
 Condenser is the heat exchanger of air condition to exchange heat to

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outdoor. Usually it is installed outdoor, so it is easy to get dirty. If the

condenser is not cleaned timely, it will affect the heat disperse level of air
condition, which will cause the condenser over pressure and the cooling
effect getting worse.
 The condenser fin is very sharp, so any incorrect operation could result in
injury. Please be very careful when cleaning the condenser. Usually, it can
be cleaned by vacuum cleaner together with nylon brush. If compressed air
available, the dust on the surface can be cleaned by the compressed air.
1.4 Drainage system inspection
 For air-condition on cranes, it is important to do periodic inspection of
drainage system. Any blockage or leakage will cause serious consequence.
 Clean the drain pan periodically. Check if there is any leakage or blockage
of drain pipe. Check if the insulation is in good level or not.
1.5 Compressor system inspection (suggested to be done by qualified air condition
technician)
 Compressor system is the heart of refrigerating system. Any small fault will
directly affect the cooling capacity.
 Check if suction pressure and discharge pressure are normal by watching
the pressure meter. Check if there is any oil leak in the system.
2 Yearly maintenance items
Besides the monthly maintenance, the following maintenance needs to be done
every year:
2.1 Check if there is any dust or mildew on the surface of evaporator. Clean it if
needed.
2.2 Check if the bearing of the fan motor wore out.
2.3 Check if the bracket of the outdoor unit is rusted.
2.4 Check if there is any loose connection of the electric wiring.
3 Appendix:

Typical Faults and Solutions

Faults Possible Cause Solutions
Air sneaks in refrigerant Draw a vacuum once more and
system charge refrigerant
Refrigerant too much Discharge excess refrigerant
High pressure Condenser too dirty Clean it
protection When the system in cooling mode,
Condensation air volume check the outdoor unit for air
inadequate flowing problems. In heating
mode, check the indoor unit.

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Faults Possible Cause Solutions

Check the flow capacity of
Liquid pipe blocked
drier-filter and expansion valve
High pressure switch fault Replace with a new one
Condensing pressure too
Check and fix
high
Discharge
Suction temperature too Refrigerant not enough, or with
temperature
high leakage or blockage
protection
Find the reason of poor lubrication
Motor overheating
and fix it
Exhaust air
temperature too Suction with liquid Check and fix
low
Refrigerant insufficient or Fix the leakage and charge
leak refrigerant
Evaporator too dirty Clean it
Evaporator with serious
Check if the defroster is working
frost
When the system in cooling mode,
Low pressure
Evaporation air volume check the outdoor unit for air
protection
inadequate flowing problems. In heating
mode, check the indoor unit.
Suction pipe blocked Check and fix
Check the flow capacity of
Liquid pipe blocked
drier-filter and expansion valve
Low pressure switch fault Replace with a new one
Compressor
Poor lubrication Check and fix
abnormal noise
Check if there is any short circuit of
Circuit breaker
Short circuit electrical wiring, or motor winding
tripped
burnt
Discharge pressure too
Check and fix
high
Suction volume and motor
Compressor Check and fix
cooling inadequate
overheating
Poor lubrication Check and fix
Axis or cylinder seized and
Replace the compressor
blocked
Temperature
sensor fault Temperature sensor fault Replace with a new one
protection
Refrigerant insufficient or Fix the leakage and charge
Cooling /heating
leak refrigerant
inadequate
Air filter too dirty Clean it.
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Faults Possible Cause Solutions

Heat exchanger too dirty Clean it
Adjust the belt tension, replace it if
Belt slipping
needed.
Check the cause of insufficient
Compressor fault
discharge volume and fix
Thermostatic expansion
Adjust it or replace it if needed
valve fault
Fan direction wrong Change its direction
Temperature sensor faulty Replace with a new one
Check the power, change the fuse
Power off or fuse broken
if needed
Wrong wiring Correct it according to the drawing
Unit not working
Under voltage Check it
Phase reversal Correct it
Last fault not reset yet Reset it
Insulating layer broken Fix it
Indoor unit not horizontal
Adjust its installation position
installed
Indoor unit water Clean the drain pan and the drain
Drainage blocked
leakage pipe
Drain pipe joints not tight Fix it and seal it
Drain pipe installed wrong
Re-design the drain pipe
way
Foreign substance inside
Remove it
Abnormal noise unit or motor
when working Poor installation of unit, or
Adjust the installation, fix the bolts
loose bolts

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VIII. LV Cabinet

The LV cabinet covers electric cabinet, operation station, module box and junction
box, etc. In order to keep crane’s normal operation, maintenance of LV cabinet is
needed to be done. When doing the maintenance, please always following the safety
regulations/rules/requirements issued by the power supply department or the customer’s
company.
1 Do periodic inspection. Check if the reading of the meter on panel door meets the
requirement of the designed capacity or not; check if indicator lights and operation
stations are normal or not; check if there is any abnormal noise, smell or temperature
or not; and check if there is serious dust deposit on the filter or not.
2 Recommend to do comprehensive maintenance every year. According the
environment and the maintenance period, the maintenance can be done as
following:
2.1 Remove dust by brush, vacuum cleaner or dry cloth. Be careful not to blow
the dust into any electric component.
2.2 Check connected screws, wiring connections, operation stations, interlock
switches. Replace it if any problem found.
2.3 Check if the insulation resistance is OK for operation. If not, check and fix it
immediately.
2.4 Replace the arc chute and insulating parts whichever broken is found.
2.5 Check grounding.
3 Periodic inspection for the operation station function, especially the seldom-used
function. The inspection can be done as following:
3.1 Emergency stop. After control on the crane, push the emergency stop on
different operation stations. Make sure the emergency stop on every
operation station is working and will trip the control as soon as it is pushed.
3.2 Lamp test pushbutton. When lamp test pushbutton is pressed, all indicator
lights should be on, and buzzer buzzing.
4 Inspection time interval
Time interval
Solutions if
Every year

running
When
months
Every 3
month
Every

When

Items Components Inspections problem

stop

found

Electric
Entire crane - - √ - √ Tighten
connection
Wiring Headblock and Electric
√ - - - √ Tighten
spreader connection
Trolley Electric - √ - - √ Tighten
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 Crane Maintenance Manual

Time interval
Solutions if

Every year

running
When
months
Every 3
month
Every

When
Items Components Inspections problem

stop
found

connection
Function - √ - - √
Switches
Cover outlook - √ - - √
Replace
Function - √ - - √
Circuit protection
Cover outlook - √ - - √
abnormal
noise or - √ - √ -
Drive fan vibration
equipments
20000 hours’
- √ - √ -
operation Replace
abnormal the fan
noise or - √ - √ -
Cabinet fan vibration
20000 hours’
- √ - √ -
operation
Over
Horizontal and - √ - √ - Check
temperature
Grounding vertical installed
Poor insulation - √ - - √ Replace
copper bar
Loose bolt - - √ - √ Tighten
Note：“√” means inspection needed, “-” means no need

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 Crane Maintenance Manual

IX. Slipping Box

1. Strictly following the relative electrical power operation safety

rules. The MV cable reel slipping box is operated only by

qualified people with guardian on site.

2. Before any maintenance of spreader cable reel slipping box,

make sure all the power circuits to the spreader cable reel

slipping box have been turned off. Especially the accessories’

circuits, such as heaters.

It is to be noticed that MV cable reel and spreader cable reel may not be provided in
some projects. Both MV cable reel and spreader cable reel are equipped with slipping
boxes. The maintenance of slipping box can be done as following:
1 The surface of slip ring should be kept clean, without any dust or oil fouling. In the
environment where the slip ring will easily get dirty, periodic inspection for the
surface of slip ring and carbon brush is needed.
2 If any spot found on surface of slip ring, please polish it with sand paper.
3 Check the carbon brush frequently to insure good contact between carbon brushes
and slip rings.
4 Check the tightening torque of every bolt in slipping box.

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 Crane Maintenance Manual

X. U-One Huebner encoder

Sometimes, the U-One Huebner encoder system needs to be adjusted, such as

changing rope, steel rope stretch after using, loose coupling of U-One Huebner encoder,
etc. Attached, please find the description for U-One Huebner encoder adjustment.

1 U-One Huebner encoder adjustment:

Items Description
1. Before changing the steel rope, put the spreader down to the ground
and leave the steel rope tensioned.
2. Upload and save the setting from the U-One Huebner encoder as
original record.
3. Bypass the cam limit switch signals in the PLC if needed, and finish
the rope changing. Bypass the hardware circuit also if needed.
4. Put the spreader down to the ground, inch the hoist to the same
position as made in “Step1”.
5. Download the original setting to the U-One Huebner encoder. Check
and verify the current online U-One Huebner encoder value is the
same as original value.
Change steel 6. Push the e-room “HOIST POSITION RESET” button about 3 second
rope for hoist position reset.
7. After that, cancel all bypasses either in software or hardware.
8. Operate the hoist motion up and down slowly to verify the setting of
the U-One Huebner encoder system. If all cam limit switch positions
are obviously different from the original, first check if the coupling
and the steel ropes are OK or not, then Repeat the above procedure
from step 4.
9. Operate the hoist in slow speed and make sure the hoist system is
OK; gradually speed up until full speed. Reconfirm the U-One
Huebner encoder system.
10. After confirming the U-One Huebner encoder system is working OK;
inform the operator that the crane can be back to service.

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 Crane Maintenance Manual

1. Steel rope will be stretched longer after certain times of using. All
cam limit switch positions will be shifted downwards. During the
operation, if no error reported because of the cam limit switch
position, do not adjust or reset the U-One Huebner encoder too
often.
2. If all positions of U-One Huebner encoder are all wrong. Before
Steel rope
adjust the cam limit switch, please observe the offset that need to be
being
adjusted and make corresponding record.
stretched
3. Put the spreader down to the ground and leave the steel rope
tensioned. Download the factory setting to the U-One Huebner
encoder and reset the hoist position.
4. Operate the hoist in slow speed and make sure the hoist system is
OK; gradually speed up until full speed
5. Repeat the above procedure if needed.
Cam limit
switch
Refer to item “Steel rope being stretched”
coupling
loose

2 Appendix： Cam Limit Switch Setting

2.1 Hoist Cam Limit Switch：

Setting PLC
Cam Function
height(m) value

1 <21>m 1 Hoist up end position

2 <18.5>m 1 Hoist up slowdown check position

3 <3>m 1 Hoist down slowdown check position

4 <0.5>m 1 Hoist down end position

5 spare

6 spare
Note:
a) The cam is numbered from the axis side.
b) The Setting height is scaled starting from ground zero, positive going above the
ground and negative below.

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 Crane Maintenance Manual

XI. Load Cell Sensor

Load cells convert load weight to electrical signal (usually 4~20mA signal). After
the electric signal goes into the PLC analog-input module, PLC calculates this
analog-input value to the load weight. If no special requirement, generally the load cell
sensor outputs 4mA when spreader on the ground and steel rope slack, 20mA when
rated load. Please find the following diagram:

Load（Ton）

Spreader + rated load

Spreader on the ground

and the steel rope slack Load cell sensor output
0 4 20 (mA)
Verify the load cells every year. Check the load cell linearity, zero load, and full load
condition with three load conditions (empty spreader, half load and rated load).
Compare the actual weight with the PLC value. If the difference is too big, please make
corresponding adjustment in PLC.

Appendix：

Typical Faults and Solutions

Faults Possible Cause Solutions
Return to the manufacturer to
Output Wrong setting of load cell sensor
reset
current lower
Wrong installation of the load cell Check the force direction and
than 4mA
sensor adjust it
Cable damaged Check the cable
Output
Internal amplifier or strain gauge
current 0mA Return to the manufacturer
damaged
Output Return to the manufacturer to
Wrong setting of load cell sensor
current higher reset
than 20mA Overload Reduce the load
Return to the manufacturer to
Wrong setting of load cell sensor
Output reset
current higher Overload Reduce the load
than 20mA or Short-circuit of the analog Check the wiring and
25mA feedback circuit connection
Internal amplifier damaged Return to the manufacturer

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 Crane Maintenance Manual

XII. Outdoor Monitoring Equipment

Attentions:
1 Dust removing work shall be taken by every season, the cameras and covers parts ．etc shall be
demounted to do dust removing by the blowers, and then using absolute alcohol cotton to wipe
up，adjusting the definition. to protect the dust entering the inner body of the equipment by
electrostatic ,and make sure that the crane running normally. Testing the technical parameters
and the cables every month according to the monitoring system specifications to try to avoid
accidents
2 Monthly checking the easily aging equipments. Change or maintain it when you find it, such as
video connectors.
3 Monthly optimizing the monitoring system: the network requirement plan should be arranged
properly, such as bandwidth, IP address etc, and the virus killing work should be done monthly.
4 Monthly providing the maintenance record: the maintenance record documents of the last month
shall be provided to the monitoring system principal at the first day of every month, first of all we
should make sure the devices working normally, then the devices can play a significant role in
safety issue.

28
CRANE MAINTENANCE MANUAL
for

SIX Ruber Tyred Gantry Cranes

For SPBUN Terminal at BUENAVENTURA

______________________________________________________________________

Shanghai Zhenhua Heavy Industries Co., Ltd.

__________________________________________________________________________

3261 Dongfang Road, Shanghai, P.R.China

Tel: 86-21-58396666

Fax: 86-21-58399555

http://www.zpmc.com