Container Gantry Crane: Maintenance

73031 HPP Maintenance
Container gantry crane

40 t x 40 / 20 / 16 m
21.07.17 1
73031 WA
© Copyright by KOCKS ARDELT KRANBAU GMBH 2017
Table of contents
1. GENERAL ................................................................................................................................................................. 3
1.1 SYMBOLS USED .................................................................................................................................................... 5
1.2 SAFETY PRECAUTIONS ......................................................................................................................................... 6
2. INSPECTIONS.......................................................................................................................................................... 7
2.1 BEARINGS ............................................................................................................................................................ 7
2.2 BRAKE SYSTEMS .................................................................................................................................................. 7
2.3 LOAD PICK-UP DEVICE ......................................................................................................................................... 7
2.3.1 Wire ropes ................................................................................................................................................... 7
2.4 BOLTS .................................................................................................................................................................. 8
2.5 MECHANICAL WEARING PARTS ............................................................................................................................ 8
2.6 OVERLOAD SAFETY DEVICE ................................................................................................................................. 8
2.7 TRANSMISSIONS ................................................................................................................................................... 8
2.8 MAINTENANCE OF THE STRUCTURAL STEELWORK ............................................................................................... 8
3. LUBRICATION AND OIL CHANGE .................................................................................................................... 9
3.1 GENERAL LUBRICATION INFORMATION ................................................................................................................ 9
3.2 GENERAL INFORMATION FOR CHANGING OILS...................................................................................................... 9
3.3 EXPLANATION OF THE LUBRICATION SCHEMES .................................................................................................. 10
3.4 IDENTIFICATION OF LUBRICATION POINTS .......................................................................................................... 11
3.5 RECOMMENDED LUBRICANTS ............................................................................................................................ 11
3.6 LUBRICATION SCHEME ....................................................................................................................................... 13
3.6.1 Lubrication scheme hoisting gear ............................................................................................................. 13
3.6.2 Lubrication scheme rope sheave system - hoisting gear ........................................................................... 15
3.6.3 Lubrication scheme boom hoisting gear ................................................................................................... 18
3.6.4 Lubrication scheme rope sheave system – boom hoist gear ...................................................................... 20
3.6.5 Lubrication scheme boom bearings .......................................................................................................... 21
3.6.6 Lubrication scheme trolley travelling gear ............................................................................................... 22
3.6.7 Lubrication scheme gantry travelling gear ............................................................................................... 23
4. MAINTENANCE OF THIRD-PARTY COMPONENTS ................................................................................... 25
5. ADJUSTMENT PROCEDURES ........................................................................................................................... 26
5.1 BRAKE SYSTEMS ................................................................................................................................................ 26
5.2 COUPLINGS ........................................................................................................................................................ 26
6. CONTROL SHEET WIRE ROPES ...................................................................................................................... 27
7. INSPECTION PLAN .............................................................................................................................................. 31
7.1 GENERAL ........................................................................................................................................................... 31
7.2 MEASURING DEVICES ......................................................................................................................................... 32
7.3 EXPLANATION OF THE INSPECTION PLAN (SAMPLE FORM) .................................................................................. 32
7.4 INSPECTION PLANS OF INDIVIDUAL COMPONENTS .............................................................................................. 33
7.4.1 Steel structure subassembly ...................................................................................................................... 33
7.4.2 Hoisting gear subassembly........................................................................................................................ 35
7.4.3 Rope sheave system hoisting gear subassembly ........................................................................................ 37
7.4.4 Boom hoisting gear subassembly .............................................................................................................. 38
7.4.5 Rope sheave system boom hoisting gear subassembly .............................................................................. 40
7.4.6 Gantry travelling gear subassembly.......................................................................................................... 41
7.4.7 Trolley travelling gear subassembly ......................................................................................................... 43
7.4.8 Cable drum system subassembly ............................................................................................................... 45
7.5 HOW TO INSPECT THIRD-PARTY COMPONENTS ................................................................................................... 46
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1. General
This section was written primarily for the maintenance engineers of the crane. In
addition, it reflects the responsibilities of the crane operators.
Naturally, both target groups must know the mode of operation of the crane.
For this reason we ask you to refer to the operating instructions of the crane.
Maintenance work at the crane shall only be carried out by qualified

technicians or especially instructed staff.
Maintenance works going beyond those described in this paragraph must be
carried out exclusively by the manufacturer or qualified service engineers.
Use only original parts for repair or replacement.
In these cases please contact:
KOCKS ARDELT KRANBAU GMBH

Weserstraße 64
D-28757 Bremen
Phone.: 0049 / (0) 421 6601 – 359 or 205 (service department)
Fax: 0049 / (0) 421 6601 – 398 (service department)
E-Mail: info@kockskrane.de
Web: //www.kranunion.de
The maintenance intervals specified below are the minimum requirements.
In unfavourable operating conditions shorter maintenance intervals must be defined.
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Maintenance works, which may be required independently from the indicated intervals:
- cleaning of the motor cooling fins *1)
- cleaning of the mechanical gears *1)
- replacing the operator's cab windscreen wiper blades
- lubricating the seat suspension (using common grease or oil)
- clean the windows of the operator's cab
- lubricating all door hinges
- filling the lubricant containers with grease (as specified)
*1) These works are required, in order to ensure efficient heat dissipation. Otherwise
overheating resulting in power losses or reduced lubrication properties resulting in
increased wear may be the consequence.
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1.1 Symbols used
Symbol for an imminent danger
You will find this symbol in all instructions on the operating safety, if there is an
imminent danger for the life and health of persons.
Any disregard of those instructions may result in heavy or critical injuries with fatal
consequences.
Symbol for indirect danger
This symbol indicates situations of indirect danger.

Extent and intensity of the damages depend on the course of originated events
and the way of reaction of the effected persons.
Any disregard of those instructions may result in damages or destruction of crane

parts or the whole crane, of other material value or in minor injuries.
Symbol for proper handling and information
This symbol points out to the necessity of complying with guidelines and rules
as well as on the proper course of works to be executed.
Additional information is given to assist you in the
optimum use of all functions of the crane.
Any disregard of those instructions may result in damages or destruction of the crane
and/or other parts of the equipment.
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1.2 Safety precautions

- Before starting maintenance works, the person responsible shall appoint the staff
and define the corresponding work. It shall have set up the necessary
demarcations and/or warning signs. The relevant safety regulations must be
observed.
- Put crane out of service. It must be reliably prevented that the crane may be put
into operation unintentionally or by an unauthorised person or that the crane may
be hit by another crane.
- Lubrication of moving parts during crane operation is permitted only, if devices are
used, which permit these works to be carried out without risk. Make sure to provide
for good communication with the crane operator.
- Observe legal accident prevention and safety regulations. Make sure to wear
protective clothing, safety goggles, safety boots or other safety equipment (safety
belts etc.), as the working conditions and the works to be accomplished may
require.
- When carrying out cleaning works with compressed air, safety goggles and
protective clothing are mandatory. The max. air pressure must not exceed 2 bars.
- Do not perform any adjustment works while the equipment is operating or the
motor is running
- Be careful while handling hot lubricants or hot parts.
- Under no circumstances oils and greases shall be allowed to penetrate into the soil
or ground water.
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2. Inspections
2.1 Bearings
Check all bearings after every 75 hours of operation and at least once a month for
excessive temperature rise during longer operation.
2.2 Brake systems

Check the brakes for proper functioning every day. In closed state the brake clips
should be in close touch with the brake disk.
Other parts of the brakes, such as levers and also Eldro parts, shall not press against
limit stops, but shall have some clearance. If the clearance is insufficient, the brakes
need to be readjusted accordingly. In lifted state the brake clips must not touch the
brake disks, but stay at a symmetrical distance from the brake disk.
The brake disk shall always have a smooth surface and shall have no scoring.
In case of excessive scoring, find out and eliminate the root cause.
2.3 Load pick-up device

2.3.1 Wire ropes
Carefully check all changes in the appearance of the ropes. Rope damages, knots and
loops shall be announced to the superior. Please pay particular attention to single
broken wires. Continuously observe the number and position of such wire breaks.
Replace the rope, if the state of the rope does not comply with the requirements of the
corresponding regulation (DIN ISO 4309).
Cast rope ends must be checked regularly for wire breaks and corrosion in particular at
the point, where the wire rope leaves the cast metal. In case of damage cut off the rope
head and renew the casting.
Detachable rope suspensions, e.g. the cable clamps on the rope drums shall be
inspected for wire breaks and corrosion in the wire rope slipping of the wire rope and
loose mounting screws.
In case of damage, cut the wire rope and attach it again, if the rope is slipping and
clamping screws are loose, retighten the connection.
Carry out the above inspections once a week.
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2.4 Bolts
After the first 250 hours of operation, check all bolts for tightness and retighten, if
necessary.
2.5 Mechanical wearing parts

Check all parts subject to wear at intervals of approx. 250 hours of operation, at least
once every three months. This applies in particular to travelling wheels (bearing surface
and wheel flanges), gears, bushes as well as hinges. Check oil radiators and gear
cases for oil leakages.
Based on our experience gathered during many years of crane manufacture, we

recommend you to make available the parts subject to intensive wear already upon
commissioning, to avoid down-times. This includes in particular hoisting ropes, brake
linings and flexible components of the shaft couplings.
2.6 Overload safety device

Check the overload safety device once in the year for proper functioning by test-loading
the crane.
2.7 Transmissions
Check oil levels, tightness of all parts, the efficiency of the ventilation system, the local
temperature rise and the noise every day. Make sure all surfaces are clean.
2.8 Maintenance of the structural steelwork

In longer time intervals the structural steelwork requires inspection. Pay special
attention to the fact that no bolted joints are loose, welded joints do not exhibit cracks,
solid wall constructions are free of buckles.
Hammer-test the steel parts to make sure that there is no corrosion below the
apparently unchanged painted finish. Also make sure there are no water
accumulations.
Before the beginning of the frost period, open the water drain holes of the hollow
sections and drain the water, if any. Then carefully seal the drain holes again.
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3. Lubrication and oil change

3.1 General lubrication information
Always use quality lubricants of renowned labels and with suitable authorisation for the
respective purpose.
We recommend you to use brands with refineries of their own. Keep lubricants always
in suitable packaging.
Make sure to store the lubricants in suitable containers. Large packages are generally
cheaper, but may be contaminated easier. Ensure cleanliness.
Comply with supplier's instructions with regard to handling, transport, storage etc.
3.2 General information for changing oils
Do not mix different oil types with each other.

When changing the oil type during oil change, make sure to clean with scavenge
oil before filling in the first oil of the new type.
For oil change the oil to be drained should be at operating temperature

(to ensure easy flow).
Make sure the drives may not be put into operation, while changing the oil.
Clean the environment of the draining, filling and control plugs as well as the level
viewing glass. Provide container for waste oil. Remove filling and draining plugs, let
waste oil safely flow into containers, provide for sufficient dripping time.
Clean or replace filters, if any and use new sealing elements. Insert oil drain plug and
wipe off any adhering oil.
Do not allow the system to be contaminated.
Fill in the specified quantity and quality of the new oil through the filling hole. Constantly
check the oil level at the viewing glass and/or control opening.
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3.3 Explanation of the lubrication schemes
The lubrication intervals are based on the operating time of the crane.
It was also assumed that the crane is used in transhipment operation and that its drives
are switched on approx. 50 % of the crane's time of operation.
The following operation hours result from a two-shift operation of the crane:
Symbol Operating hours
per day (T) 16 h
per week (W) 100 h
per month (M) 400 h
two months (2M) 800 h
Two and a half month (2,5M) 1100 h
Three months (Q) 1200 h
six months (H) 2500 h
per year (J) 5000 h
general repair (G) G
Cranes, which do not achieve the above operation times shall be re-lubricated as
indicated by the symbols.
Do not mix different oil types with each other. When changing the oil type during
oil change, make sure to clean with scavenge oil before filling in the first oil of
the new type.
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3.4 Identification of lubrication points
The symbols shown in the device column of the lubrication schemes have the following
meaning:
Symbol Lubricating device
E filling plug
F flat type lubricating nipple
Z central lubrication system
AS automatic lubrication feeder
3.5 Recommended lubricants
In the table below the lubricants selected by the manufacturer are shown in bold letters.
Any substitution of these oils and/or greases by other lubricants specified in the table is
permissible only after express confirmation of the compatibility of the lubricants by both
lubricant manufacturers.
If in doubt, contact the manufacturer's customer service.
Do not mix synthetic oils with mineral oils.
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Sym- Shell Aral BP Esso M/s. M/s. M/s.

bol Optimol K.S. Paul Fuchs
Lubritech
a Omala Aral Energol Spartan Optimol Klüber-

Öl 220 Degol GR-XP 220 EP 220 Optigear Synth
BG 220 BM220 EG 4-150
b Omala Aral Energol Spartan Optimol

Öl 320 Degol GR-XP 320 EP 320 Optigear
BG 320 BM320
c Alvania RL3 Grease Energrease Beacon 3

HL3 LS2
d Malleus OGH Energrease Unirex N3 Ceplattyn

(old name: LS-EP2 BL
Grease
S8327)
e Calithia EP Aralup Energrease Beacon

Fett T2 HLP2 LS-EP2 EP2
f Alvania WR3
g Retinax AM
h Alvania Energrease
EP Grease 2 LS-EP2
i PBC Gleitmo
(Poly- WSP 5040
Butyl
Cuprysil)
k Cardium Aralup Energrease Surret Ceplattyn

Fluid C LFZ1 OG Fluid 4K 300
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3.6 Lubrication scheme

3.6.1 Lubrication scheme hoisting gear
Item Point of lubrication Lubricant Lubri- Lubri- Lubricants

No. cation cating (kg)
intervals device initial current
(h) demand demand
1 rope pressure device c 800 (2M) - - 0,1

joints
2 rope pressure device c 800 (2M) F - 0,1

pressure roller
3 rope drum roller c G - - 0,5

bearing
4 transmission gear oil a 1000 (2,5M) E see manufacturer's

change documentation
5 transmission gear, refill a 100 (W) E see manufacturer's

oil as required documentation
6 joints of brake linkage c 800 (2M) - - 0,2

and Elhy
7 oil change a 2500 (H) E see manufacturer's

safety brake documentation
8 Cardan shaft c 1200 (Q) F see manufacturer's

documentation
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Lubrication scheme hoisting gear
8 6 4, 5 1 2 3
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3.6.2 Lubrication scheme rope sheave system - hoisting gear

(h) demand demand
1 joints fixed point of rope c 800 (2M) F 0,2 0,2
2 joints fixed point of rope c 800 (2M) F 0,2 0,2
3 clamp bolts c 800 (2M) - 0,2 0,1
4 clamp bolts c 800 (2M) - 0,2 0,1
5 joints c 800 (2M) F 0,2 0,2

rope passage
6 rope sheave support - c 800 (2M) F 1 0,1

headblock
7 rope sheave support - c 800 (2M) F 1 0,1

headblock
8 rope sheaves c 800 (2M) F 5 1

- hoisting gear
- rope passage
- bridge girder end LS
- trolley
- headblock
9 wire ropes, re-lubricate d 800 (2M) - 8 2

as required
10 pin connection c 800 (2M) - 0,2 0,1

spreader- headblock
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Lubrication scheme rope sheave system - hoisting gear
1, 2, 3, 4 5 8
9 6, 7, 8, 10 8
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Lubrication scheme rope sheave system - hoisting gear

(h) demand demand
1 Spindle of the k 800 (2M) - 0,1 0,1

adjustment unit
2-5 joints of the c 800 (2M) F 0,2 0,2

rope sheave support
6 spindle lifting gear after documentation

SHZ-350 company ZIMM
4, 5
2, 3
1 6
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3.6.3 Lubrication scheme boom hoisting gear

(h) demand demand
1 anti-friction bearing c G - - 0,5

rope drum
2 transmission gear oil a 1000 E see manufacturer's

change (2,5M) documentation
3 transmission gear, refill a 100 (W) E see manufacturer's

4 joints of brake linkage c 800 (2M) - - 0,2

and Elhy
5 oil change a 5000 (J) E see manufacturer's

safety brake documentation
6 bevel gear, oil change a 5000 (J) E see manufacturer's

documentation
7 bevel gear, refill a 100 (W) E see manufacturer's

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6,7 4 2, 3 5
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3.6.4 Lubrication scheme rope sheave system – boom hoist gear

(h) demand demand
1 joints fixed point of rope c 800 (2M) - 0,2 0,2
2 joints fork sleeve c 800 (2M) - 0,2 0,2
3 rope sheaves c 800 (2M) F 1 0,5

- pylon
- boom
- rope passage
4 joints rope passage c 800 (2M) F 0,2 0,2
5 wire ropes, re-lubricate d 800 (2M) - 8 2

as required
6 Bearing of boom latch c 800 (2M) F 0,2 0,2
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3.6.5 Lubrication scheme boom bearings

(h) demand demand
1 bearing pylon - tension plate c 2500 (H) F - 0,2
2 bearing boom - tension plate c 2500 (H) F - 0,2
3 bearing tension plate c 2500 (H) F - 0,5
4 bearing boom c 2500 (H) F - 0,5
1
3
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3.6.6 Lubrication scheme trolley travelling gear

(h) demand demand
1 bearing trolley suspension c 5000 (J) F - 1
2 bearing of the c 5000 (J) F - 1

travelling wheels
3 bearing of the guide rollers c 5000 (J) F - 0,5
4 gearing: oil change a 5000 (J) according to

documentation
Ma. Siemens /
Flender
5 gearing: check oil level and a 400 (M) according to

refill as required documentation
Ma. Siemens /
Flender
3 2 4, 5
1 1
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3.6.7 Lubrication scheme gantry travelling gear

(h) demand demand
1 gearing: oil change according to documentation Ma. Siemens / Flender
2 gearing: check oil level according to documentation Ma. Siemens / Flender

and refill as required
3 rail tong Tellus T68 see documentation CTHV – M/s. Hillmar
4 bearing c 5000 (J) F - 0,2

travelling wheel
balancer-
intermediate balancer
5 bearing c 5000 (J) F - 0,2

intermediate balancer
main balancer
6 bearing c 5000 (J) F - 0,2

main balancer-
sill beam
7 bearings of the c 5000 (J) F - 1

travelling wheels
8 teeth profiles of the d 400 (M) - 2 2

transmission pinion and
ring gears of the
travelling wheels
9 Bearings of pinion drive c 5000 (J) - - 0,2

shaft
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Lubrication scheme gantry travelling gear
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4. Maintenance of third-party components
Third-party components shall be maintained on the basis of the documentation of the

corresponding manufacturer. Such documentation is included in the item
"Documentation of mechanical third party components" (73031 BD) of the operating
manual.
This applies mainly to the following components:
Brake systems
Couplings
Transmissions
Overload safety device
Wire rope
Rail clamps
Cable drum
Repair crane
Lift
Spreader
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5. Adjustment procedures
5.1 Brake systems
See documentation disk brake, drum brake and double shoe brake
Ma. Siegerland
See documentation disk brake

Ma. Bubenzer
5.2 Couplings
See documentation brake disc coupling Ma. Reich
See documentation elastic bolt coupling of Ma. Pritzwalk
See documentation electromagnetical toothed coupling of Ma. Stromag
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6. Control sheet wire ropes
Control sheet wire ropes
Order-No. 73031 Sub- rope sheave system hoisting gear

Code word HPP assembly
make of rope 28-1960sZ-bk left-handed

nominal diameter [mm] 28 right-handed x
strength [N/mm²] 1960 twist in opposite x
direction
rope length [m] 230 twist in same
direction
blank x
galvanised
kind of end fastening on one rope end with full thimble 28 DIN 3091 execution: Flemish eye
presented to working hours
measured wire breaks wear corrosio diameter miscella-

place n dia. reduction nous
on 6 x d on 30 x d * * mm / % **
Overall evaluation: Date:
Signature:
* description such as no, less, moderate, strong, very strong, to be replaced

** remark such as notice on rope deformation
Side
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Order-No. 73031 Sub- rope sheave system hoisting gear

make of rope 28-1960zS-bk left-handed x

nominal diameter [mm] 28 right-handed
direction
direction
blank x
galvanised
kind of end fastening on one rope end with full thimble 28 DIN 3091 execution: Flemish eye

on 6 x d on 30 x d * * mm / % **
Signature:

Side
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Order-No. 73031 Sub- rope sheave system boom hoisting gear

make of rope 30-1770sZ-bk left-handed

nominal diameter [mm] 30 right-handed x
direction
direction
blank x
galvanised
kind of end fastening on one rope end with open spelter socket GSHVZ111BMS

on 6 x d on 30 x d * * mm / % **
Signature:

Side
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Order-No. 73031 Sub- rope sheave system boom hoisting gear

make of rope 30-1770zS-bk left-handed x

nominal diameter [mm] 30 right-handed
direction
direction
blank x
galvanised
kind of end fastening on one rope end with open spelter socket GSHVZ111BMS

on 6 x d on 30 x d * * mm / % **
Signature:

Side
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7. Inspection plan
7.1 General
The specified inspection intervals have been designed for the crane.
Regular inspections increase the safety and the service life of the crane.
By exactly specifying the inspections, the scope of works of the maintenance staff is
clearly defined.
The inspection results shall be suitably documented and filed.

We recommend using the inspection form provided under item 7.3.
Only use original parts.

Immediately communicate any safety relevant malfunctions to the customer
service of KOCKS ARDELT KRANBAU GMBH
Before continuing crane operation, contact the manufacturer.
The inspection records shall be made available to the manufacturer upon

request.
Evaluation of the inspection results may influence the manufacturer's actions to be
taken with regard to the crane.
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7.2 Measuring devices
Inspections will require the following measuring devices:
main measuring device: folding rule, measuring tape of steel, vernier caliper,
feeler gage
special measuring devices: specified in inspection plans
7.3 Explanation of the inspection plan (sample form)
S1 ... = steel construction
M1 ... = mechanical engineering
o = to be checked once per shift, record results in inspection plan in the time
marked with "X"
x = inspection results must be recorded in the inspection plan
S = shift
W = week
2M = two months
J = annually
Example of an inspection record form:

item inspection inspection measured special recommended
no. process interval value measuring inspection
S W 2M J nominal devices procedure
M1 function of the o x
brake
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7.4 Inspection plans of individual components

7.4.1 Steel structure subassembly
item inspection procedure inspection measured special recommended

no. interval value measuring inspection
S1 checking whether all . . . x 1 months after

screws are fastened commissioning of
the crane and
after that as
specified under x
S2 water drainage in the . . . x visual inspection

upper chord of the free movement
gantry girder
S3 checking of the screwed . . . x visual inspection

connections at the
bearing points of the
forestay and backstay
are fastened
S4 checking wear of the . . . x visual inspection

rail rolling surface
S5 random test method . . . x 1 months after

checking of the bolt commissioning of
connection at the the crane and
trolley after that as
specified under x
S6 checking all components . . . x visual inspection

for signs of corrosion
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Steel structure subassembly

S7 checking of the passage x . . . visual inspection

blocking between function
trolley and gantry on their
performance
S8 checking of following
sub-assembly or
transitions to welding
seam tears
- tension members . . . x
travelling gear bearing
connection
- gantry frame . . . x visual inspection

support LS + WS of the welded
seams and the

- gantry girder . . . x substrate
- gantry girder stairs . . . x
- stairs support WS . . . x
- stairs support LS . . . x
- trolley - load bearing . . . x

structure
S9 checking all . . . x visual inspection

fastening bolts
stairs and platforms
are fastened
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7.4.2 Hoisting gear subassembly

M1 disk brake performance o x . .

and the hydraulic
aggregate
operating manual
for disk brake
M2 wear of break linings . x . . min. Ma. Bubenzer
(minimum lining 4 mm and
thickness) Ma. Siegerland
M3 check remaining stroke X . x . .
M4 tight fit of brake disks . . . x visual inspection

and
elastic couplings
M5 performance of the o x . . check indicator

overload safety device light
M6 check of the overload . . . x test loads drawing of the

safety device overload safety
device
M7 performance of the rope . x . . visual inspection

pressure device
M8 tight fit of rope clamps on . . x . see notes torque drawings

rope drums wrench mentioned in it
M9 tight fit of fastening bolts . . x . torque

at the motor wrench
M 10 control of the fastening . . . x torque drawings

bolts of the bearing block wrench mentioned in it
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Hoisting gear subassembly

M 11 tight fit of all fastening . . x . visual inspection

screws
M 12 check slack rope . . x . functional test

switching-off
M 14 performance of the . . x . visual inspection

limit switches and the
centrifugal switch
M 15 switching points of the o x . . crane

limit switch composition
M 16 check transmission gear . . x . visual inspection

for oil leakage
M 17 performance of the . . x . functional test

shifting coupling
M 18 performance oil cooling . . x . visual inspection

gearing as well as
connection of the lines
for tightness
M 19 lubricate unit . . . . according to

lubrication
scheme
M 20 check all components for . . . x visual inspection

corrosion and damage
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7.4.3 Rope sheave system hoisting gear subassembly

M1 rope wear . x . . see catalogue

(Control sheet wire ropes) "Inspection of
wire ropes"
or DIN 15020
part 2
M2 rope end fastening, . . x . visual inspection

adjustable
M3 headblocks . . x . visual inspection

function control
M4 fork sleeve of the wires . . x . wear wear of the basic

rope < 10 % cross section
M5 lubricate unit . . . . according to

lubrication
scheme
M6 check all components for . . . x visual inspection

M7 rope sheaves . . x . visual inspection

function control
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7.4.4 Boom hoisting gear subassembly

M1 performance of the drum o x . .

brakes and disk brakes
of
the hydraulic aggregate operating manual
for drum brake

M2 wear of break linings . x . . min. and disk brake
(minimum lining 4 mm Ma. Siegerland
thickness)
M3 check remaining stroke X . x . .
M4 tight fit of brake disks . . . x visual inspection

and
elastic bolt couplings
M5 tight fit of fastening bolts . . x . torque drawing

at the motor wrench hoisting gear
M6 control of the fastening . . . x torque drawings

bolts of the bearing block wrench mentioned in it
21.07.17 38
73031 WA
Boom hoisting gear subassembly

M7 tight fit of all fastening . . x . visual inspection

screws
M8 performance of the . . x . visual inspection

limit switches and the
centrifugal switch
M9 switching points of the o x . . according to

limit switch crane
composition

for oil leakage
M 11 performance oil cooling . . x . visual inspection

gearing as well as
connection of the lines
for tightness

lubrication
scheme

21.07.17 39
73031 WA
7.4.5 Rope sheave system boom hoisting gear subassembly

M1 rope wear . x . . see catalogue

(Control sheet wire ropes) "Inspection of
wire ropes"
or DIN 15020
part 2
M2 rope end fastening . . x . visual inspection
M3 rope sheaves . . x . visual inspection

function control
M4 fork sleeve of the wires . . x . wear wear of the basic

rope < 10 % cross section
M5 lubricate unit . . . . according to

lubrication
scheme

21.07.17 40
73031 WA
7.4.6 Gantry travelling gear subassembly

M1 brake performance o x . . according to

(brake motor) operating manual
M2 wear of the friction . . x . according to

linings operating manual
(minimum lining engine supplier
thickness)
M3 tight fit the travelling . . . x visual inspection

wheel and balancer
axles
M4 rail tong performance o x . . visual inspection

according to
operating manual
Ma. Hillmar
M5 wear of travelling wheel . . . x 12,5 mm visual inspection

flange (min. permitted
wheel flange thickness)
M6 external visual inspection . . . x tears,

of travelling gear deformations
balancers
M7 visual inspection . . . x tears,

torque support deformations
21.07.17 41
73031 WA
Gantry travelling gear subassembly

M8 tight fit drive unit on the . . . x visual inspection

drive shaft
M9 tight fit of all fastening . . x .

bolts
M 10 pretension moments of . . x . torque according to

the fastening bolts with wrench drawing
pretension moments


lubrication
scheme
M 13 switch point of limit . . x . according to

switch for travelling gear adjustment
regulation
M 14 check laying of crane . . . x according to

rails crane
composition
a) gauge
b) rail slope
c) transversal slope
21.07.17 42
73031 WA
7.4.7 Trolley travelling gear subassembly

M1 brake performance o x . .
M2 wear of the brake linings . . x . according to

operating manual
Ma. Siemens /
Flender
M3 tight fit the torque . . x . visual inspection

support
M4 performance of the guide . . . x visual inspection

rollers
M5 wear guide roller . . . x 250 mm visual inspection

in the outside diameter
M6 tight fit the travelling . . . x visual inspection

wheel and balancer
axles
M7 tight fit of all fastening . . . x visual inspection

bolts
M8 check tightening torque . . . x drawings

of all pre-stressed bolts mentioned in it

21.07.17 43
73031 WA
Trolley travelling gear subassembly

M 10 performance of the limit . x . . according to

switching trolley adjustment
travelling gear regulation
M 11 attitude of the guide . . x . 2 +/- Total play

rollers 1 mm between guide
in closest roller and web
place trolley rail

for oil leakage

lubrication
scheme
21.07.17 44
73031 WA
7.4.8 Cable drum system subassembly

M1 motor cable drum . . . .

performance
see
M2 check firm fit of motor . . x . documentation
cable drum on motor cable
drum
M3 check firm fit of reversing . . x .

unit / guide roller
M4 reversal unit / guide roller . . x . easy movement

performance
M5 check for loose fastening . . x .

bolts
M6 check all components for . . x . visual inspection

M7 lubricate unit . . . . see

documentation
on motor cable
drum
21.07.17 45
73031 WA
7.5 How to inspect third-party components

Third-party components shall be inspected on the basis of the documentation of the
corresponding manufacturer. Such documentation is included in the item "Documentation of
mechanical third party components" (73031 BD) of the operating manual.
21.07.17 46
73031 WA

Container Gantry Crane: Maintenance

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Container Gantry Crane: Maintenance

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73031 HPP Maintenance

Container gantry crane

Maintenance work at the crane shall only be carried out by qualified

Use only original parts for repair or replacement.

In these cases please contact:

KOCKS ARDELT KRANBAU GMBH

Fax: 0049 / (0) 421 6601 – 398 (service department)

The maintenance intervals specified below are the minimum requirements.

In unfavourable operating conditions shorter maintenance intervals must be defined.

- cleaning of the mechanical gears *1)

- replacing the operator's cab windscreen wiper blades

- lubricating the seat suspension (using common grease or oil)

- clean the windows of the operator's cab

- lubricating all door hinges

- filling the lubricant containers with grease (as specified)

1.1 Symbols used

Symbol for an imminent danger

Symbol for indirect danger

This symbol indicates situations of indirect danger.

Any disregard of those instructions may result in damages or destruction of crane

Symbol for proper handling and information

1.2 Safety precautions

2.2 Brake systems

2.3 Load pick-up device

Carry out the above inspections once a week.

2.5 Mechanical wearing parts

Based on our experience gathered during many years of crane manufacture, we

2.6 Overload safety device

2.8 Maintenance of the structural steelwork

3. Lubrication and oil change

3.2 General information for changing oils

Do not mix different oil types with each other.

For oil change the oil to be drained should be at operating temperature

Do not allow the system to be contaminated.

3.3 Explanation of the lubrication schemes

Symbol Operating hours

per day (T) 16 h

per week (W) 100 h

per month (M) 400 h

two months (2M) 800 h

Two and a half month (2,5M) 1100 h

Three months (Q) 1200 h

six months (H) 2500 h

per year (J) 5000 h

general repair (G) G

3.4 Identification of lubrication points

Symbol Lubricating device

F flat type lubricating nipple

Z central lubrication system

AS automatic lubrication feeder

3.5 Recommended lubricants

If in doubt, contact the manufacturer's customer service.

Do not mix synthetic oils with mineral oils.

Sym- Shell Aral BP Esso M/s. M/s. M/s.

a Omala Aral Energol Spartan Optimol Klüber-

b Omala Aral Energol Spartan Optimol

c Alvania RL3 Grease Energrease Beacon 3

d Malleus OGH Energrease Unirex N3 Ceplattyn

e Calithia EP Aralup Energrease Beacon

k Cardium Aralup Energrease Surret Ceplattyn

3.6 Lubrication scheme

Item Point of lubrication Lubricant Lubri- Lubri- Lubricants

1 rope pressure device c 800 (2M) - - 0,1