KONECRANES RTG Maintenance Manual

Pivot Locking Motor ...........................................................83

Table of Contents Replacing the Motor...........................................................85

GEAR BOXES ______________________87

READ THIS FIRST 3 Construction of KONECRANES Gear Unit ........................87
Inspection and Maintenance..............................................88
SAFETY INFORMATION .................................................... 3 Storage of the Spare Gear Reducer ..................................88
About This Manual .............................................................. 4 Procedure for Initial Use of the Gear Unit ..........................89
Installing Gear Box.............................................................89
PREVENTIVE MAINTENANCE 5 gearbox Operation .............................................................89

COUPLINGS _______________________91
INTRODUCTION_____________________5 Gantry Motor Coupling.......................................................91
Locking Device Coupling ...................................................94
INTRODUCTION TO ROUTINE Hoist Motor Coupling (GO1-AMM).....................................97
Hoist Drum Coupling..........................................................99
INSPECTIONS ______________________6
General................................................................................ 6 GANTRY BOGIE___________________103
Inspection Schedule ............................................................ 6
General ............................................................................103
Required Tools For Maintenance ........................................ 7
Replacing Gantry Travel Machinery.................................105
Inspection Sheets................................................................ 8
Inspection and Maintenance............................................107
LUBRICATION______________________17 INSPECTION OF MISC
Lubrication Schedule......................................................... 17
TABLE - Recommended Lubricants .................................. 18
COMPONENTS____________________109
Lubrication Point Location Drawings ................................. 25 Fire Extinquishers ............................................................109
Read This Before Lubricating............................................ 30 Control Equipment Ventilation .........................................110
Gear Box Lubrication (IN 1)............................................... 30 Inspection of the Resistor Banks .....................................111
TABLE - Gear Box Oil Quantities ...................................... 32
Motor Bearing Lubrication (IN 2) ....................................... 32
CAB WINDOW CLEANING__________113
Linkage & Limit Switch Lubrication (IN 3).......................... 33
Wire Rope Lubrication (IN 4) ............................................. 34 SPECIAL PROCEDURES 115
Lubricating Couplings in Trolley (IN 5) .............................. 35
Lubricating Couplings In Bogie (IN 6)................................ 36
Encoder/ Limit Switch Gear lubrication (IN 7) ................... 38 A. STRUCTURAL INSPECTION _____115
Inspection Methods..........................................................115
WIRE ROPE INSPECTIONS _________39 Frequency of Inspection...................................................117
Wire Rope Inspection Requirements................................. 39 Inspection for Fatigue Crack Growth ...............................118
Visual Inspections for Each Rope ..................................... 39 Inspection for Corrosion...................................................119
Rope Diameter Measurements ......................................... 42 Repair of Damages ..........................................................120
Clamp Tightness Checks for Each Rope .......................... 43 Inspection and Tightening of Bolted Joints ......................122
Wire Rope Inspection Plan................................................ 44 TABLE - Bolt Tightening Torques ....................................123
Structural Inspection Plan................................................128
HOIST BRAKE (BUBENZER) _________45 Inspection of Multiple Components..................................128
Inspection of Multiple Components..................................129
HOIST BRAKE (PINTSCH-BAMAG) ___45
Installing the Hoist Brake................................................... 49 B. END CARRIAGE & RAIL WHEEL
Commissioning the Brake ................................................. 53 ALIGNMENT ______________________143
Manual Release ................................................................ 57 Aligning Equipment..........................................................143
Hoist Brake Inspection and Maintenance.......................... 59 Aligning Principles of the Wheels ....................................144
Hoist Brake Removal......................................................... 66 Effectiveness of Adjustment Achieved by the Eccentricity144
Axial Adjustment ..............................................................147
GANTRY, TROLLEY TRAVERSE AND Final Measurements ........................................................147
AUXILIARY WINCH BRAKE __________67
Structure and functional Description ................................. 67 C. ROPE CHANGE_________________151
Brake Structure ................................................................. 68 TABLE – Rope Data ........................................................151
Brake Coding..................................................................... 68 Procurement of Ropes .....................................................152
Electrical Connections....................................................... 68 Preparing the Rope..........................................................152
Manual Hand Release....................................................... 69 Safety Precautions before Rope Change ........................155
Inspecting Brakes (ACM, Trolley, Gantry) ......................... 69 Local Control of Hoist Drives ...........................................156
Adjustment of Braking Torque........................................... 71 Local Control of Auxiliary Winch Drives ...........................156
TABLE - Brake data .......................................................... 71 Temporary Hoist or Reeving Winch .................................156
Temporary Reeving Rope (Aux. Ropes)..........................157
MOTORS __________________________73 Removal of Old Ropes.....................................................157
Inspection and Maintenance ............................................. 74 Installation of New Ropes ................................................160
Hoist Motor ........................................................................ 76 Raising A New Rope........................................................161
Gantry Travel Motor........................................................... 79
ACM And Trolley Traverse Motor ...................................... 81 D. HOIST ROPE ADJUSTMENT _____167
 KONECRANES RTG Maintenance Manual

Rope Balance Adjustment............................................... 168 GUIDE TO MAINTENANCE LEVEL

Rope Balance Check....................................................... 168
Limit Switch Checking / Adjustment ................................ 169
FUNCTIONS ______________________225
Lists of Maintenance Display Screens .............................226
E. SPREADER CABLE CHANGE ___ 173 Counter / Hour Screens ...................................................237
Introduction...................................................................... 173 Information Display Screens ............................................243
New Spreader Cable Procurement.................................. 173 Bypass and Setting Screens............................................249
Safety Precautions before Cable Change ....................... 174 Operational Display Screens ...........................................253
Old Spreader Cable Removal ......................................... 175 Setting Op. panel Password ............................................261
Installation of New Spreader Cable ................................. 176
Final Visual Inspection .................................................... 182
APPENDIX A. CONVERSION TABLES263
Functional Testing ........................................................... 182

F. BOGIE JACKINGS ______________ 183

Introduction...................................................................... 183
Safety Precautions - Before Jacking ............................... 183
Safety Precautions - During Adverse Conditions ............ 184
Preparations Before Jacking ........................................... 185

WHEEL CHANGE (FLAT TIRE) _____ 185

Introduction...................................................................... 185
Bogie Jacking Details ...................................................... 185
Wheel Pair Jacking Procedure ........................................ 186
Wheel Removal ............................................................... 187
Puncture Repair / Tyre Change....................................... 188
Wheel Re-Fitting.............................................................. 188
TABLE - Tire Pressure .................................................... 188
Wheel Nuts Tightening .................................................... 189
Jack Removal.................................................................. 189

JACKING THE WHOLE BOGIE _____ 190

Introduction...................................................................... 190
Motor + Brake Removal - Outer Bogie ............................ 190
Jacking Procedure........................................................... 191
Gearbox / King Pin Lowering Details............................... 192

G. TROLLEY WHEELS / BEARINGS

CHANGING ______________________ 193
Introduction...................................................................... 193
Safety precautions - Before Jacking the Trolley .............. 194
Trolley Jacking ................................................................ 194

H. LOAD CONTROL AND POS.

MEASUREMENTS ________________ 197
Load Measurement and Calculation................................ 197
Load Indication Displays ................................................. 198
Slack Rope Detection...................................................... 198
Overload Protection......................................................... 199
Load Cells Calibration ..................................................... 201
Hoist Speed Supervision ................................................. 201
Hoist Position Calibration ................................................ 202
Trolley Position Calibration.............................................. 202

I. DIRECT MOTOR CONTROL______ 203

J. LOCAL HOIST CONTROL _______ 205
K. SOLVING STEERING PROBLEMS 207
Correcting the Bogie Steering Angle ............................... 207
Jammed Steering Lock.................................................... 208

L. PLC AND DISPLAY PANEL ______ 211

PLC Display Panel (OP270) ............................................ 211
Keys on the PLC Display Panel....................................... 212
Event Pages - "K1" Function Key .................................... 220
Alarm Pages - "K2" Function Key.................................... 222
Help Window (Additional Information) ............................. 224
 RTG Maintenance Vol 2 – Preventive Maintenance – Safety Information 3

READ THIS FIRST

SAFETY INFORMATION
IMPORTANT! The safety information provided here is
of a general nature. Special safety
information is provided at specific point
in the text.
Observing all safety information will
help prevent dangers to the life and
health of persons as well as damage to
the crane and environment.
Safety rules and regulations must
also be observed under the
pressure of time. Accidents cannot
be reversed.
Always observe the local safety rules
and instructions.

Power Supply Whenever possible, the relevant motions and drives are
prevented from operating by isolating their electrical
supplies.
Make sure that RTG is secured to prevent accidental
activation of power supply.
Note that voltages can be present in the crane after
switching off the diesel engine.
Make sure that crane is not connected to the aux. diesel or
shore power supply (optional features).
Special Care with The safety from moving or rotating machinery must be
Moving or ensured. Before servicing a component make sure that the
Rotating shaft is prevented from rotating by locking it and isolating the
Machinery electrical power to the corresponding motors.
Do NOT remove the component while there is any external
torque applied to the shaft.
Working Area Mark out a sufficiently sized working area. Prevent outsiders
accidentaly accessing the site. A safety distance should be
maintained to all hazardous zones.
Servicing a A specific component may be dismantled to the extent
component specifield in the instructions. Any dismantling of the
assemblies over and beyond the extent specified is
forbidden. Refrain from any actions that could affect the
safety of the component.
Flammable Do not store any flammable objects in the crane.
Objects
Work with care Before carrying out any work on the crane take the following
measures:
- Wear only closed, suitable shoes in a perfect condition
 RTG Maintenance Vol 2 – Preventive Maintenance – Safety Information 4

and closed, tight-fitting working clothes.

- Long hair must be tied back.
- Work should only be carried out on the electrical, moving
or rotating component when:
- All dangerous movements have stopped
- Accidental and unexpected operation of the
component or module is made impossible by
suitable measures
- If the component is loaded, other safety devices
must act as the braking and holding function.
Danger of Particular attention should be paid, especially when working
crushing with heavy tools, to possible crushing points.

ABOUT THIS MANUAL

The lengths, weights, torques, forces, temperatures and speeds are presented in
both metric and US units. In case of disparities between these units the metric values
are the ruling ones.
 RTG Maintenance Vol 2 – Preventive Maintenance – Inspections 5

PREVENTIVE MAINTENANCE

INTRODUCTION
To keep the crane in good working order, adequate routine maintenance must be
carried out at regular intervals.
This is necessary to guarantee a continued high level of reliability and availability.
It is also important for ensuring the safety of all persons working in the vicinity of
the crane.
The total requirements for all routine maintenance activities on the crane are
brought together in this single manual.
Where the routine maintenance is to be carried out by a specialist sub-contractor,
this manual can be used to fully define the extent of the work.
The preventive maintenance part is divided in the following sections:

Section Section Includes

Introduction to Inspection schedules
Routine Inspections Inspection sheets
Lubrication Recommended lubricants
Lubrication point location drawings.
Lubricating procedures
Wire Rope Inspections Inspection requirements
Visual inspection procedure
Rope diameter measurement procedure
Checking the clamp tightness
Rope defects
Rope & Clamp datasheet
Brakes Inspection and maintenance procedures for brakes
Brake datasheet
Motors Inspection and maintenance procedures for motors
Assembly and disassembly of motors
Gear Boxes Inspection and maintenance procedures for gears
Couplings Inspection and maintenance procedures for couplings
Gantry Bogie Inspection of gantry travelling machinery
Inspection of Misc Fire extinquisher inspection
Equipment Ventilation Inspection
Brake resistor bank inspection
 RTG Maintenance Vol 2 – Preventive Maintenance – Inspections 6

INTRODUCTION TO ROUTINE
INSPECTIONS
GENERAL
Before the Crane is started, the Operator should carry out the pre-start checks as
described in the User's Manual (Volume 1). During these checks, the Operator
should also identify any components that have been mechanically damaged, or
fixings that are loose or detached.
In addition to the visual checks carried out by the Operator, the components of
the Crane must be inspected on a routine basis. The person carrying out each of
these inspections must be suitably qualified and experienced.
The Inspection Schedule lists the items which require routine inspection.
The intervals are also chosen to be the same as those for the routine lubrication.
‘Hours’ interval refers to diesel hours.
The inspection procedures are based on "best practices" and are chosen to give a
high general standard of safety and reliability for the crane. They include the tests
and calibrations of safety protection systems.
There may be local statutory requirements which apply to the inspections, tests or
calibrations of the complete crane or just to certain items of equipment.
Satisfying these specific requirements is the responsibility of the User.
If necessary, the routine maintenance procedures must be supplemented to meet
them.
Note that the absence of statutory requirements should not be taken by the User
to permit any reduction in the routine maintenance requirements.

INSPECTION SCHEDULE
The items which require routine inspection are listed in the following schedule with
inspection intervals.

Interval Description
Every 100 hours All components are given a general visual inspection.
Every 250 hours While each item of machinery is running, the components are
given a visual inspection and an aural check to listen for
internal defects.
Every 750 hours The components that can wear during normal operation are
inspected. The air filters are also checked and any clogged
ones are cleaned or replaced as appropriate.
Every 6000 hours The other components that require specialist measurements
or other calibration tests are inspected at this major service
interval.
Calendar Based Brakes, ropes, ventilation and fire extinquishers must be
inspected within calendar based time interval in case the
RTG Maintenance Vol 2 – Preventive Maintenance – Inspections 7

hour interval has not been completed.

Note: Hour intervals may vary depending on the type and nature of
the operation.
In case the RTG is hasn’t been in operation for a long period
of time (1 month) it’s recommended to go through the ‘250
hours’ visual inspections even the hour intervals haven’t
been completed.
For the general inspections, the schedule includes a brief description of the
requirements against each respective plant item.
For specific inspections, the schedule includes a cross reference to the section in
this manual which contains the inspection procedure.
In the case of the structural inspections, these require different tests on certain
welds or components at varying intervals. This cannot be accommodated easily
within the format of the main inspection schedule. Instead, the structural
inspection procedure is described separately in ‘Special Procedures’ section.

REQUIRED TOOLS FOR MAINTENANCE

Following is a list that covers the most common standard tools required in the
routine and special maintenance procedures.

Side cutter 1 pcs Testing probe Fluke 1AC 1 pcs

Power side cutter 1 pcs Ballhead hammer 900 g 1 pcs
Set of pliers 2 units Keyhead hammer 2000 g 1 pcs
Set of head pliers 2 units Chisel 125 mm 1 pcs
Set of lock ring pliers, inside 3 units Chisel 175 mm 1 pcs
Set of lock ring pliers, outside 3 units Punch set 1 pcs
End sleeve grimping tool 1 pcs Flat file 1 pcs
Pipe pliers 310 mm 1 pcs Round file 1 pcs
Allen key set (1,5–14 mm, 9/64) 1 set Round file 1 pcs
Water pump plier set 2 units Triangle file 1
Spanner set (6x7...30x32 mm) 1 set pcs
Fork wrenches set (8x9..30x32) 1 set Small heck saw 1 pcs
Set of spanners (6 ...36 mm) 1 set Drillbits 6 pcs 1 pcs
Chisel 46 mm 1 pcs Heck saw 1 pcs
Chisel 50 mm 1 pcs Hardmetal scraper 1 pcs
Chisel 55 mm 1 pcs Hardmetal drillbit 25 mm 1 pcs
Ratchet ½” 1 pcs Ruler 3 m 1 pcs
½” extension 255 mm 1 pcs Vernier caliber Mauser 150 mm 1 pcs
Socket wrench set (10..36 mm) 1 set Micrometer Digital 1 pcs
Ratchet handle 17x19 1 pcs Digital Multimeter Fluke 187 1 pcs
Ratchet ¾” 1 pcs Clamp-on AC/DC Ammeter 1 pcs
¾” extension 200 mm 1 pcs 500V insulation tester megger 1 pcs
Torgue wrench 80-400 Nm 1 pcs Flashlight 1 pcs
Conversion head ¾” 14x18 1 pcs Angle grinder 1 pcs
Torgue multiplier 1 pcs Electric drill 1 pcs
Screw driver PH2/100 1 pcs Drillbit set 1-15 mm 1 pcs
Screw driver PH3/150 1 pcs Impact wrench ½” 1 pcs
Screw driver PH4/200 1 pcs Impact gun socket set 10-24 mm 1 set
Screw driver 4x100 1 pcs Hose 16 mm 10 m 1 set
Screw driver 6,5x150 1 pcs Precision torque wr. 300-940Nm 1 pcs
Screw driver 8x200 1 pcs Socket wr. set ¾” 27,30,32,36 1 set
Water/Vacuum cleaner 1 pcs
RTG Maintenance Vol 2 – Preventive Maintenance – Inspections 8

INSPECTION SHEETS
It is recommended that the person carrying out the inspections should record that
the checks have been carried out.
Following are the inspection sheets which show the time interval, type and and
location for the inspection. These sheets can be used as check lists: make copies
of each page and fill in the header information prior inspecting, tick mark the last
column after the item has been checked.
When a defect is found during the inspections, it is important that the necessary
action is taken to remedy it.
Note: One module can have differerent time intervals and different types of
inspections. Read the header information carefully.

READ THIS BEFORE STARTING

WARNING ! Read the Safety Precautions at the beginning of this
manual.

While Maintenance Personnel are inspecting the crane

care must be taken to avoid an accident.

During visual & aural inspections when the RTG is

running the safety from moving or rotating machinery
must be ensured.

During inspections when the RTG is not running all of

the relevant motions and drives must be prevented
from operating by isolating their electrical supplies.
Make also sure that RTG is secured to prevent
accidental activation of power supply.
 RTG Maintenance Vol 2 – Preventive Maintenance – Inspections 9

Date: Prev. Inpection, date:

Inpected By: Prev. Inspection, D-hrs:

Diesel hrs now: Next Inspect. date, est:

BOGIE
EVERY 100 Hrs VISUAL&AURAL INSPECTION (RTG NOT OK
RUNNING)
Bogie Wheels All tyres are in good condition. O
All tires are inflated to the correct pressure. O
Wheel rims are not damaged. O
There are no loose or missing wheel nuts or hub bearing
O
covers.
Bogie Motors There are no loose or missing fixings. O
The flexible cables to each bogie are not damaged. O
Bogie Gearboxes There are no oil leaks. O
Bogie Balancing The plates locating the pivot pins are in place and the fixings
O
Beam Pivot Joints are tight.
Pivot Locking Dev. There are no loose or missing fixings. O
Steering Pos. Limit There is no mechanical damage and that the spring return
Sw. & Encoder, limit switches operate freely. O
Rack Wheel
"Cat's Whisker" There is no mechanical damage and that the spring return to
O
Limit Switches the centre position operates freely. (Optional Item)
Ultrasonic Collision There is no mechanical damage. (Optional Item)
O
Protection Units.
EVERY 250 Hrs VISUAL & AURAL INSPECTION (RTG RUNNING) OK
Gantry Travel While the gantry is travelling, check that there is no excessive
O
noise from its bogie drives or wheel bearings.
All of the brakes release fully. O
The travel warning lights and sounds operate correctly. O
Bogie Steering Change the gantry travel mode so that the steering angle is
O
changed for each bogie.
Each bogie steering turns freely, with no excessive noise from
O
the kingpin bearings.
Each steering lock operates correctly during the steering
O
direction changes.
Check wear rate of bushings. Replace, if damaged. (Refer to
‘Special Procedures’ – Steering Problems – Replacement of O
pivot locking bushing)
 RTG Maintenance Vol 2 – Preventive Maintenance – Inspections 10

Date: Prev. Inpection, date:

Inpected By: Prev. Inspection, D-hrs:

Diesel hrs now: Next Inspect. date, est:

MAIN DIESEL ALTERNATOR (+AUX.)

EVERY 100 Hrs VISUAL INSPECTION (RTG NOT RUNNING) O
K
Main + Aux There are no leaks from the oil lubrication system. O
(Optional) Diesel There are no leaks from the diesel fuel system. O
Alternator Check the level of the coolant.
If necessary, add more coolant with the correct concentration O
Warning! of anti- freeze / corrosion inhibitor.
During these There are no leaks in coolant system O
checks, the engine
The drive belts for the cooling fan and for the battery charging
must be prevented O
alternator are in good condition.
from operating (local
emergency stop Check the condition of the water separator.
O
button pressed). If necessary, drain off any collected water.
The air filter "clogged" indicator has not operated. If
O
necessary, fit a new replacement air filter element.
After inspection is completed make sure that the covers for
the enclosure are in place and that the local emergency stop O
button is released.
Repeat the procedure with auxiliary diesel (optional) when
O
applicable
Shore Power Cable There is no damage to the cable. O
(Optional) The limit switch operates correctly when the plug is inserted
O
into its stowage socket.
EVERY 250 Hrs VISUAL INSPECTION (RTG NOT RUNNING) O
K
Main + Aux. The drive belts for the cooling fan and for the battery charging
O
(optional) Diesel alternator are correctly tensioned.
Alternator Check the condition of the air cleaner element. If necessary,
O
Warning! fit a new replacement element.
During these Check the level of the electrolyte in each battery cell.
checks, the engine If necessary, add more distiled water (not applicable to O
must be prevented maintenance free batteries).
from operating (local
emergency stop When the inspection is completed, make sure that the covers
button pressed). for the enclosure are in place and that the local emergency O
stop button is released.
Repeat the procedure with auxiliary diesel (optional) where
O
applicable
 RTG Maintenance Vol 2 – Preventive Maintenance – Inspections 11

Date: Prev. Inpection, date:

Inpected By: Prev. Inspection, D-hrs:

Diesel hrs now: Next Inspect. date, est:

MAIN DIESEL ALTERNATOR

EVERY 250 Hrs VISUAL & AURAL INSPECTION (RTG RUNNING) OK
Main Diesel There are no exhaust system leaks from the pipes or from the
O
Alternator silencer.
There are no excessive noises from the engine, including the
: valve gear,
exhaust manifolds,
turbo charger,
O
water pump bearings,
fan bearings,
battery charging alternator bearings /
brushgear.
There are no excessive noises from the main alternator
bearings. O

OPERATOR’S CAB, ACCESS ROUTE

EVERY 100 Hrs GENERAL VISUAL INSPECTION OK
Op. Cab Access The proximity limit switches operate correctly when the
O
Gate Prox. L. Sw. access gates are opened and closed.
Op. Cab Windows Windows are not broken. O
Operator's Cab The wipers operate. O
Windscreen Wipers The wiper blades are not damaged. O
and Washers The washers operate correctly. O
Access Walkways & There is no mechanical damage. O
Stairways, incl. There are no loose or missing fixings. O
Hand Rails There is no loose debris, tools, or other parts. O
Access Lights All access lights work correctly. O
ACM Cable Guards The guards for auxiliary winch ropes are not damaged. O
 RTG Maintenance Vol 2 – Preventive Maintenance – Inspections 12

Date: Prev. Inpection, date:

Inpected By: Prev. Inspection, D-hrs:

Diesel hrs now: Next Inspect. date, est:

TROLLEY, MAIN GIRDER

EVERY 100 Hrs GENERAL VISUAL INSPECTION OK
Flood Lights All flood lights work correctly. O
Trolley Rails The rails are not damaged. O
Trolley Wheels The wheel flanges are not damaged. There are no loose
O
attachment bolts nor securing screws
End Carriages There are no loose or missing fixings. O
Trolley Trav. Gears There are no oil leaks. O
Trolley Buffers The buffers are not damaged. O
There are no loose or missing fixings. O
Trolley Pos. L. Sw. The prox. sw. and activating plates are not damaged. O
Trolley Position The pulse encoder unit is correctly mounted onto the end of
O
Pulse Encoder one trolley traverse motor (E2).
Cable Track There is no damage to the flexible cables nor to the sliding
O
pads under the track.
The links in the cable track are not damaged and no link pins
O
are missing.
There is no damage in the flex. cable supporting drum. O
Hoist Speed The pulse encoder unit is correctly mounted onto the end of
O
Measurement Unit the motor. Note: Both hoists.
Hoist Drive There are no oil leaks from the gearbox (both hoists). O
Machinery There are no loose or missing fixings (both hoists). O
Hoist Position Pulse The combined limit switches / absolute encoder unit is
Encoder / Limit correctly mounted. Drive gears from the intermediate shaft of O
Switches the gearbox are not damaged. (Both hoists)
Hoist Drum The hoist and aux. ropes are correctly wound onto drum’s
O
(Both Hoists) spiral grooves and rope end clamps are tight.
There are no loose or missing fixings in drum coupling. O
There no loose or missing fixings in drum bearing. O
Hoist Rope Load The load cell is mounted correctly, with no mechanical
O
Cell damage. Note: Four hoist rope load cells.
Aux. Winch Speed The pulse encoder unit is correctly mounted onto the end of
O
Measurement Unit the motor. Note: Each winch.
Aux. Winch There are no oil leaks from the gearbox. (Each winch) O
Machinery There are no loose or missing fixings. (Each winch) O
Auxi. Winch Drum The aux. rope is correctly wound onto drum’s spiral groove
O
and rope end clamps are tight. (Each winch.)
 RTG Maintenance Vol 2 – Preventive Maintenance – Inspections 13

Date: Prev. Inpection, date:

Inpected By: Prev. Inspection, D-hrs:

Diesel hrs now: Next Inspect. date, est:

TROLLEY
EVERY 500 VISUAL & AURAL INSPECTION (RTG RUNNING) OK
Hrs
Trolley Traverse While the trolley is traversing, check that there is no excessive
O
noise from the motors nor wheel bearings.
The cable track and the supporting drum operates freely. O
Hoist Machinery While the hoists are operating, check that there is no excessive
O
(Both Hoists) noise from motor / gear box.
The hoist ropes and the auxiliary ropes run freely on and off
O
each hoist drum.
All of the pulleys run freely, with no excessive noise from the
O
bearings.
The brakes release fully. O
The spreader cable coils correctly into its basket on the spreader
O
head block.
Operate the hoists until the motors reach their working
temperature and check that each motor cooling fan runs with no O
excessive noise from its bearings.
Auxiliary Winches While the auxiliary winches are operating during spreader fine
positioning, check that the auxiliary ropes run freely on and off O
each winch drum.
The brake releases fully on each winch. O

SPREADER (CHECK MANUFACT. MANUAL)

EVERY 250 Hrs VISUAL & AURAL INSPECTION (RTG RUNNING) OK
Telescopic The hydraulic unit runs without excessive noise from the
O
Spreader bearings or from the pump.
All four feeler pins move freely (spreader not resting on a
O
container).
While the spreader is resting on a container, check that the
O
twist- locks operate correctly with no seized linkages.
Each pair of flippers operates correctly. O
Change the spreader length and check that the telescopic
O
mechanism runs freely in both directions.
 RTG Maintenance Vol 2 – Preventive Maintenance – Inspections 14

Date: Prev. Inpection, date:

Inpected By: Prev. Inspection, D-hrs:

Diesel hrs now: Next Inspect. date, est:

TROLLEY
1 M OR 250 Hrs* ITEM PROCEDURE OK
Fire Protection Eq. Fire Extinguishers ‘Inspection of Misc. Comp.’ – O
Fire Extinquishers
Wire Ropes Hoist Ropes (4 x) ‘Wire Rope Inspection’ –
Auxiliary Ropes (4 x) Visual
3 M OR 750 Hrs* ITEM PROCEDURE OK
Wire Ropes Hoist Ropes (4 x) ‘Wire Rope Inspections’ – O
Auxiliary Ropes (4 x) Rope diam. & Clamp tightnss O
Brakes Hoist (2 x) ‘Brakes’ – Hoist Brake O
Gantry Travel (8 x) ‘Brakes’ – Gantry, Trolley O
Auxiliary Winch (4 x) Traverse and Aux. Winch O
Trolley Traverse (4 x) Brake O
Ventilation Equipment Cubicles ‘Inspection of Misc. Comp.’ –
O
Ventilation
12 M OR 3000 Hrs* ITEM PROCEDURE OK
Motors Hoist (2 x) O
Trolley traverse (4 x) O
‘Motors’-
ACM (4 x) Inspection and Maintenance O
Gantry Travel (4 x) O
Gear Hoist (2 x) O
Trolley traverse (4 x) ‘Gears’- O
ACM (4 x) Inspection and Maintenance O
Gantry (8 x) O
Couplings Hoist Motor (2 x) O
Hoist Drum (2 x) ‘Couplings’ >Coupling Type< O
Gantry Motor (8 x) ‘Inspection and Maintenance’ O
Locking Device (8 x) O
Brake Resistor Banks Brake resistors on e-room ‘Inspection of Misc. Comp.’ –
O
and on trolley cubicle Brake Resistor Banks
Fire Protection Eq. Fire Extinguishers ‘Inspection of Misc. Comp.’ –
O
Fire Extinquishers
Steel Structures Structural Inspection ‘Special Procedures’ –
O
A. Structural Inspection
Indication / Hoist Rope Imbalance ‘Special Procedures’ -
Protection Equipment Measurement (4 x) D. Hoist Rope Adjustment – O
Rope Imbalance Meas.
* Which ever comes first (M = Months)
 RTG Maintenance Vol 2 – Preventive Maintenance – Inspections 15

NOTE: For diesel-alternator, spreader and air conditioning onspection,

please refer to separate manufacturer's operation and
maintenance manuals

Date: Prev. Inpection, date:

Inpected By: Prev. Inspection, D-hrs:

Diesel hrs now: Next Inspect. date, est:

ENERGY CHAIN
Warning!
Accidental operation of crane shall be prevented during these checks by pressing
the local emergency stop button.

1 W OR 50 Hrs* PROCEDURE OK
Channel Guide O
(In dirty or dusty environment daily)
Cable Chain
Check if there is foreign objects or dirt in the channel guide or
on the chain and remove them. Remove all dust and dirt. If O
excessive dirt has accumulated the reason should be cleared
and inspection intervals shortened when necessary.

1 M OR 250 Hrs* PROCEDURE OK

Gliding Skids Check that the gliding skids and the link connection pins are not O
Link Connection damaged. Replace them if necessary. Also visually check the O
Pins side band and the cross pieces, and the cables/hoses carried in
Side Band the chain. Check that the cable/hose attachments are well O
Cross Pieces tightened and in working order. If the cross-pieces have screw O
Electrical Cables fastenings, visually check that the screws are not loose. O
Fastening Screws Note: screw fastenings directly into the nylon (without threaded
nuts) must not be overtightened! O
6 M OR 1500 Hrs* PROCEDURE OK
Bending Radius of
Check and measure the bending radius of the chain and the
Chain
clearance beetween the links of the chain. In clean conditions and
(does not apply
with loads allowed for the specific chain type wear should be O
cases with stainless
extremely small, many millions work cycles are quite normal. Dirt,
steel drum inside
dust, cable/hose problems and special ambient conditions can,
the chain)
however cause higher than normal wear. If excessive wear is found
Clearance the reason for this should be cleared.
between Links Due to wear the bending radius of the chain can become smaller.
Verify that the bending radius has not changed significantly from the
design radius, and that it is always bigger than the bending radius of
the cables. O
Wear can also, after extremely long time of use, cause the clearance
between the links to become bigger. If this is big enough to influence
chain working the side band should be renewed.

* Which ever comes first (M = Months, W = Week)

 RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 17

LUBRICATION
LUBRICATION SCHEDULE
The lubrication schedule for routine maintenance is based on activities at several
different intervals:

For diesel, spreader and air conditioning inspections

please refer to manufacturer’s original manuals.

Every 250 Hours The fluid levels in the gearboxes and hydraulic unit
or 1 Month* reservoirs are checked and replenished if necessary.
The oil is changed (or sampled) in the diesel engine.

Every 750 Hours The general routine grease-gun and oil-can lubrication is
or 3 Months* carried out. This ensures that all components of the
crane are kept in good working order.

Every 3000 The major lubrication is carried out. At this time, most of
Hours or 1 Year* the lubricating oils and greases are changed.
Note that some components may need to be partially
dismantled to carry out the major lubrication.

* Which ever comes first.

In addition to these time intervals, the lubrication schedule is further sub-divided
into groups of plant items that require the same type and grade of lubricant.
The lubrication schedule contains an entry for each plant item that must be
lubricated at a particular time interval.
For each item, a cross reference is provided to the layout drawing at the end of
the Lubrication section. The reference includes the part number which shows the
exact location of the lubrication point.
A separate cross reference is also given to the section of this manual which
contains the lubrication procedure. Where a common procedure can be used for a
number of similar plant items, a cross reference to the section is also included.
The "Recommended Lubricants" lists of suitable oils, greases and hydraulic fluids
are detailed in the Lubrication section. For each group of applications, lubricants
from a number of manufacturers are included. These are selected after the
consideration of the ambient temperature range at the site.
Note that in certain cases, the recommended lubricant may be different from that
listed in the equipment manufacturer's data sheets. These variations have only
been made after the careful consideration of the duty for each item of equipment,
and after consultation with the equipment manufacturer. The changes usually
allow a single lubricant to be used over a wider range of ambient temperature.
The spreader and diesel lubrication information is exluded in this section and
original manufacturer’s manuals must be referred for lubricating information.
RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 18

TABLE - RECOMMENDED LUBRICANTS

LUBRICANT GROUPS
Group No Applies to Used
Product
1 Gears, splash lubrication, transmission chains
2 Worm gears, splash lubrication
3 Anti-friction and plain bearings, grease
lubrication
4a Open gear wheels
4b Steel wire ropes
5 Electro-hydraulic thrustors
6 Hydraulic systems
7 Guide rails for conveyor chains
8 Central lubrication system, grease lubrication
10 Light oli can
11 Grease packed couplings
Some of the lubricants in group 4 contain a diluent which evaporates after smearing.
In this case, they must be smeared 4-8 hours before the device is commissioned.
Under normal operating conditions it is acceptable to use one oil year-round, when
appropriate. This also pertains to outdoor applications. If only one oil is to be used,
select the oil based on the summer temperature. Verify that the lowest operating
temperature during the winter is sufficiently above the drip point.

ISO-VISCOSITY CLASSES FOR INDUSTRIAL OILS

There are 18 ISO-viscosity classes. The viscosity of each class is approximately
50 % higher than that of the preceding class. The limit values are ± 10 % of the
average viscosity value. The following table gives the values for the 12 viscosity
classes used by Konecranes.

ISO-viscosity class Average Viscosity limit values cSt / 40 oC

(ISO 3448-1975) viscosity
cSt / 40 oC Min. Max.
ISO VG 7 6.8 6.12 7.48
ISO VG 10 10 9.0 11.0
ISO VG 15 15 13.5 16.5
ISO VG 22 22 19.8 24.2
ISO VG 32 32 28.8 35.2
ISO VG 46 46 41.4 50.6
ISO VG 68 68 61.2 74.8
ISO VG 100 100 90 110
ISO VG 150 150 135 165
ISO VG 220 220 198 242
ISO VG 320 320 288 352
ISO VG 460 460 414 506
 RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 19

GROUP 1: GEARS, SPLASH LUBR., TRANSMISSION CHAINS

The following EP-gear assembly oils withstand high pressures. Note that these
oils contain additives.
Viscosity Manufacturer´s Manufacturer´s product no 1) Congltion Operating
cSt/40 oC product name Environment temperature C o point temp.
range
o o
-30..+5 -5..+35 +15..+60 C C
ISO 65 BP Energol GR-XP 68 -30
VG 68 Castrol Alpha ZN (ISO)
68 65 Esso Spartan 68 -33 -20..+ 60
64 Gulf EP Lubricant HD 68 -36
65 Mobilgear 68 -33 -30..+110
Neste vaihteisto 68 EP 626 -30
68 Shell Omala Oil 68 -32 -22..+120
71 Teboil Pressure Oil 68 -27
53 Texaco Meropa 68 -34
68
ISO 140 BP Energol GR-XP 150 (ISO) -27
VG 150 Castrol Alpha ZN 150
150 140 Esso Spartan 150 -27 -15..+ 80
160 Esso Spartan Synthetic EP 150 150 -42 -25..+100
147 Gulf EP Lubricant HD 150 -30
142 Mobilgear 629 -24 -20..+110
Neste vaihteisto 150 EP 150 -24
Neste vaihteisto S 150 EP S150 S150 -48
146 Shell Tivela Oil (150) SA -33 -23..+170
150 Shell Omala Oil 150 -25 -15..+120
150 Shell Paolina 150 150 150 -51 -40..+140
Teboil Pressure Oil 150 -21
Teboil Sypres 150 150 -48
135 Texaco Meropa 150 -27
Mobilgear SHC 150 150 -55
ISO 210 BP Energol GR-XP 220 (ISO) -27
VG 230 Castrol Alpha ZN 220
220 225 Esso Spartan 220 -21 0..+100
232 Esso Spartan Synthetic EP 220 -39 -15..+110
219 Gulf EP Lubricant HD 220 -15
209 Mobilgear 630 -23 -10..+110
Neste vaihteisto 220 EP 220 -21
Neste vaihteisto S 220 EP S220 -45
220 Shell Omala Oil 220 -18 - 8..+120
220 Shell Paolina 220 220 220 -48 -35..+150
214 Shell Tivela Oil (220) WB -32 -22..+170
Teboil Pressure Oil 220 -18
Teboil Sypres 220 -39
190 Texaco Meropa 220 -21
Mobilgear SHC 220 -51

1) The product numbers within parentheses do not cover the whole

environment temperature range.
If a longer oil change interval is required, or it is necessary to use the same
oil for a wider temperature range, oils with synthetic and metallic additives
are recommended for use. In these cases, the oil change interval,
operating temperature range and compatibility with the sealing materials
and interior paint of the gear assembly must be clarified with the oil
supplier.
 RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 20

GROUP 2: WORM GEARS, SPLASH LUBRICATION

These EP-gear assembly oils, which contain additives, withstand high pressures.
Viscosity Manufacturer´s Manufacturer´s product Congltion Operating
cSt/40 oC product name number point temp.
Environment temperature oC range
o o
-30..+5 -5..+35 +15..+60 C C
ISO 65 BP Energol GR-XP 68 (ISO) -30 .. +110
VG 68 Castrol Alpha ZN 68
68 65 Esso Spartan 68 -33 -20..+ 60
64 Gulf EP Lubricant HD 68 -36
65 Mobilgear 626 -33 -30..+110
Neste vaihteisto 68 EP 68 -30
68 Shell Omala Oil 68 -32 -22..+120
71 Teboil Pressure Oil 68 -27
53 Texaco Meropa 68 -34
ISO 210 BP Energol GR-XP 220 (ISO) -27 ..+110
VG 230 Castrol Alpha ZN 220
220 225 Esso Spartan 220 -21 0..+100
232 Esso Spartan Synthetic EP 220 -39 -15..+110
219 Gulf EP Lubricant HD 220 -15
209 Mobilgear 630 -23 -10..+110
Neste vaihteisto 220 EP 220 -21
Neste vaihteisto S 220 EP S220 -45
220 Shell Omala Oil 220 -18 - 8..+120
220 Shell Paolina 220 220 -48 -25..+150
220 Shell Tivela Oil (220) WB -32 -22..+170
Teboil Pressure Oil 220 -18
Teboil Sypres 220 -39
190 Texaco Meropa 220 -21
220 TOTAL CARTER EP 220 -12
225 Mobil Glygoyle 30 30 -31 -20..+220
ISO 305 BP Energol GR-XP 320 (ISO) -24 0..+100
VG 330 Castrol Alpha ZN 320
320 337 Esso Spartan 320 -18 + 5..+120
309 Gulf EP Lubricant HD 320 -12
304 Mobilgear 632 -18 0..+110
Neste vaihteisto 320 EP 320 -12
320 Shell Omala Oil 320 -15 - 5..+120
320 Shell Paolina 320 320 -48 -15..+160
328 Shell Tivela Oil (320) SD (320) SD -36 -10..+120
Teboil Pressure Oil 320 -15
330 Texaco Meropa 320 -18
320 TOTAL CARTER EP 320 -12

If a longer oil change interval is required, or it is necessary to use the same

oil for a wider temperature range, oils with synthetic and metallic additives
are recommended for use. In these cases, the oil change interval, operating
temperature range and compatibility with the sealing materials and interior
paint of the gear assembly must be clarified with the oil supplier.
 RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 21

GROUP 3: ANTI-FRICTION AND PLAIN BEARINGS, GREASE

LUBRICATION
These greases are intended for lubrication of anti-friction and plain bearings. Due
to their wide operating temperature range and good water resistance, they may
be used as multi-purpose greases. The graphite grease is not recommended for
anti-friction bearings.
Manufacturer´s Manufacturer´s product number Dropping Op. temp.
product name Environment temperature oC point range
o o
-30..+5 -5..+35 +15..+60 C C
A. BP Energrease LS2 LS2 LS2 190 -30..+130
Universal Castrol Spheerol AP2 AP2 AP2 175
greases Esso Beacon 2 2 2 185 -40..+120
Esso Beacon EP2 EP2 EP2 185 -30..+125
Esso Unirex N2 N2 N2 304 -30..+165
Gulfcrown Grease LE No. 2 No. 2 193 -20..+120
Mobil Mobilgrease 1275 1275 1275 -30..+200
Shell Alvania EP Grease MP MP MP 170 -30..+120
Shell Alvania EP Grease 1 180 -30..+100
Shell Syntix 2 2 180 -20..+120
TB Multi-Purpose 460 460 460
Texaco Multifak Grease Grease Grease 185 -30..+110
2 2 2 200 -30..+120
B. BP Energrease LS1 LS1 170 -50..+ 80
Antifreez Esso Unirex Grease Grease Grease 260 -60..+ 80
e Esso Unirex Lotemp EP S2 S2 S2 >260 -50..+220
greases LE 3751 3751 3751 282 -45..+300
Mobil Mobilgrease 28 28 28 260 -55..+180
Shell Albida Grease HLS HLS HLS >260 -30..+170
Shell Alvania EP Grease 1 1 180 -30..+110
Shell Grease Syntix 100 100 100 260 -40..+150
TB O-Grease O-Grease 190 -50..+ 80
Texaco All Temp Grease Grease 282 -54..+ 80

GROUP 4 A: OPEN GEAR WHEELS

These greases are often bitumen-based and contain mixtures i.e. molybdenum
sulfide and, at times, graphite. They are also used as protective grease for
compensating chains.
Manufacturer´s Manufacturer´s product number Dropping Op. temp. Note!
product name Environment temperature oC point range
o o
-30 ... +5 -5 ... +35 +15 ... +60 C C
BP Energol GR 3000-2 3000-2 3000-2 14
Castrol Grippa 33 33 must be
Esso EOL 232 232 232 none -30 ... +300 heated
Gulf Lubcote No. 3 No. 3 0 ... +200
LE 185 185 185 -35 ... + 92
Mobil Mobiltac 81 81 81 260 -30 ... +140
Shell Malleus GL 95 GL 95 -20 ... +200
Shell Kuggfett Kuggfett Kuggfett none -40 ... +300
TB Gear Grease MDS MDS MDS none -35 ... +300
Texaco Crater 1 1 1
 RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 22

GROUP 4 B: STEEL WIRE ROPES

Manufacturer´s Manufacturer´s product number Dropping Operating Note!

product name Environment temperature oC point temp. range
o o
-30 ... +5 -5 ... +35 +15 ... +60 C C
BP Energol GR 3000-2 3000-2 60
Esso EOL 232 232 232 none -30 ... +300 must be
Gulf Lubcote NR1 NR1 NR1 -40 ... +100 heated
LE 450L 450L 450L -25 ... + 70
Mobil Mobilarma 798 798 798 63 -40 ... + 60
Shell Ensis Fluid K K K - -40 ... +100
TB Gear Grease MDS MDS MDS none -35 ... +300
Tekno-Spray LPS3 LPS3 -50 ... +280

GROUP 5: ELECTRO-HYDRAULIC THRUSTORS

Transformer oil whose congelation point is low may be used in electro-hydraulic
thrustors. Hydraulic oils are recommended due the good resistance to disruptive
electrical discharge and low congelation point.

Viscosity Manufacturer´s Manufact. product no 1) Congltion Viscosity Op.

cSt/40 oC product name Environment temp. oC point index temp.
range
o o
-30..+5 -5..+35 +15..+60 C VI C
ISO 14 BP Energol SHF (LT15) LT15 (LT15) -51 >300 -25..+50
VG 8 Mobilect 44 44 -56 70 -40..
15 13 Esso Univis J13 J13 (J13) < -59 378 -30..+50
15 Esso Univis N15 N15 (N15) -48 157
22 Esso Univis (N22) N22 N22 -48 145
8.8 Shell Diala Oil DX DX -45
10 Shell Morlina 10 -57 61
13.8 Shell Aero Shell Fluid 4 -60 410V/E -30..+50
10.6 Tebo Larita Oil (10) (10) (10) -54 85 -25..+50
14.4 Tebo Hydraulic Artz oil oil oil -60 395 -30..+50
ISO 35 BP Energol SHF - - 32 -36 180 + 6..+60
VG 30 Gulf Hydraulic Oil - - 32 -51 181 + 6..+60
32 32 Shell Tellus Oil - T32 super -42 195
32 Shell Tellus Oil - - -33 105
29.3 Tebo Hydraulic Oil - - S32 -54 180 + 6..+60
32S

1) The product numbers within parentheses do not cover the whole

environment temperature range.
 RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 23

GROUP 6: HYDRAULIC SYSTEMS

The high viscosity index of these hydraulic oils allow them to be used at varying
and low temperatures. The maximum permissible momentary temperature of the
oil is + 60 oC.
Viscosity Manufacturer´s Manufacturer´s product no 1) Congltn Visc. Note!
cSt/40 oC product name Environment temperature oC point index 1)
o
-30..+5 -5..+35 +15..+60 C VI
ISO 14 BP Energol SHF LT15 (ISO) LT15 (ISO) -51 300
VG 14.5 Castrol Hyspin AWH 15 15 -51 147
15 15 Esso Univis N15 N15 -48 157
26 Esso Hydraulic Oil J26 J26 J26 < -59 395
16 Mobil DTE 11 11 -44 159
15 Shell Tellus Oil T15 <-51 153
12 TB Hydraulic Oil 15 15 -60 170
ISO 35 BP Energol SHF 32 (ISO) 32 (ISO) -36 180
VG 31.8 Esso Univis (N32) N32 N32 -45 152
32 31 Gulf Harmony 32AW 32AW -30 112
29 Mobil DTE 13 13 13 -45 151
30 Shell Tellus Oil T32 -42 153
31 TB Hydraulic Oil 32 32 -51 150
32 Texaco Rando Oil HD-AZ HD-AZ -39 200
ISO 43 BP Energol SHF 46 (ISO) 46 (ISO) -36 160
VG 42 Castrol Hyspin AWH 46 46 -33 152
46 45.7 Esso Univis N46 N46 -39 151
44 Gulf Harmony 46AW 46AW -30 113
43 Mobil DTE 15 15 -45 158
46 Shell Tellus Oil T46 -39 154
43 TB Hydraulic Oil 46 46 -54 160

1) The product numbers within parentheses do not cover the whole

environment temperature range.

GROUP 7: GUIDE RAILS FOR CONVEYOR CHAINS

Lubricants according to group 1 are used.
 RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 24

GROUP 8: CENTRAL LUBRICATION SYSTEM, GREASE

LUBRICATED
These greases have good pumping capability. They contain pressure resistant
additives.
Manufacturer´s Manufacturer´s product number Dropping Op. temp.
product name Environment temperature oC point range
o o
-30..+5 -5..+35 +15..+60 C C
A. BP Energrease PR-EP1 95 -20..+ 50
Universal- Esso Beacon EP1 EP1 185 -10..+125
greases Esso Beacon EP0 EP0 185 -10..+120
Esso Beacon EP2 185 + 5..+125
Gulfcrown Grease LE EP1 EP1 195 -20..+120
Mobil Mobilplex 4701 4701 4701
Mobil Mobilux EP 47 47 47 260 -30..+140
Shell Alvania EP Grs. 2 2 180 -20..+130
TB Multi-Purpose 2 2 180
Texaco Multifak Extra Extra Extra 190 -35..+110
EP1 EP1 EP1 183 -30..+120
B. BP Energrease FGL 95 -30..+ 30
Antifreeze Esso Unirex Grease Grease Grease 260 -40..+ 80
greases Esso EGL Lotemp EP 3818A 3818A 3818A 180 -40..+100
Mobil Mobilplex 45 45 45 260 -30..+130
Mobil Mobilux EP 1 1 1 170 -30..+120
Arctic-Grease
Shell Alvania EP Grs. O 175 -30..+100
Shell Alvania EP Grs. 1 1 180 -30..+110
Shell Grease Centra W W 200 -40..+100
TB O-Grease O-Grease 190 -50..+ 80

GROUP 10: LIGHT OIL CAN

Castrol TXT 5W-40
Castrol GTX3 15W-40
Esso (Exxon) Extra Motor Oil 10W-30
Esso (Exxon) Super Oil 10W-40
Mobil Special 10W-30
Mobil Super 10W-40
Mobil Super 15W-50
Neste Beta 10W-40
Neste Gamma 10W-30
Shell Super Plus 10W-40
Castrol RS 5W-50 SYNTHETIC
Castrol RS 10W-60 SYNTHETIC
Esso (Exxon) Ultra Oil 10W-30 SYNTHETIC
Mobil One 5W-30 SYNTHETIC
Mobil One Rally Formula 5W-50 SYNTHETIC
Neste Alpha 1 10W-30 SYNTHETIC
Neste Alpha 2 10W-40 SYNTHETIC
Shell Helix 10W-40 SYNTHETIC
Shell TMO 5W-30 SYNTHETIC
RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 25

GROUP 11: GREASE PACKED COUPLINGS

Manufacturer´s Manufacturer´s product number
product name
Environment temperature oC –20 ... +70
AGIP GR-MU/EP
CHEVRON DURA LIGHT GREASE-EP
MONTESHELL ALVANIA-EP
IP ATHESIA-EP
MOBIL MOBILTEMP 78
ESSO BEACON-EP

LUBRICATION POINT LOCATION DRAWINGS

This section includes drawings of the RTG modules to assist in finding the exact
locations of the lubrication points.
The lubrication points are showed with an item number. Each drawing has an
itemized table listing the points and showing the quantity of each item. Grease
nipples are identified with letter "N".
Note that some other maintenance items are also be identified on the drawings
and in the tables. These may not require lubrication.

RTG Module Drawing Reference

Trolley and Operator’s Cab LU1
Bogies / Steering LU2
Head Block LU3
Gantry LU4
 RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 26

TROLLEY AND OPERATOR’S CAB LUBRICATION POINTS (LU1)

3 9
1 HOIST MACHINERY
(2 PCS)

10

33

32

AUXILIARY
22, 24 WINCH (4 PCS)

40, 41, 42

9
HOIST ROPE 6
ATTACHMENT (4 PCS)
TROLLEY TRAVERSE
MACHINERY (4 PCS)
61 62

Equipment Ref Item Procedure Quantity OK

Hoist Machinery 3 Gearbox * 0500-HOIL-01 2
O
6000-R-01
10 Drum bearing 1500-GG-03 2 x 1N O
2 Motor coupling * 1500-GG-11 2 x 1N O
9 Drum coupling * 1500-GG-11 2 x 1N O
6 Open gear transmission * 6000-GB-4A 2 O
1 Motor bearings * 6000-GG-03 2 x 2N O
Auxiliary Winch 22 Gearbox * 0500-HOIL-01 4
O
Machinery 6000-R-01
24 Auxiliary rope * 1500-GB-4B 4 O
Trolley Traverse 32 Gearbox * 0500-HOIL-01 4
O
Machinery 6000-R-01
33 Wheel bearings 1500-GG-03 4 x 2N O
Hoist Ropes / 40 Hoist Rope * 1500-GB-4B 4 O
Attachments 41 Wedged head fitting 1500-CAN-10 4 O
42 Load cell 1500-CAN-10 4 O
Operator's Cab 61 Cab attachment pins 1500-CAN-10 1 O
62 Cab door & window hinges 1500-GG-11 12 x 1N O
Procedure Definition: H-LP-LG LP. ID Lubricating Procedure Description
H = Hour Interval (500-6000) GG Grease Gun Application
LP = Lubricating Procedure GB Grease Brush Application
LG = Lubricant Group CAN Oil-Can Application
HOIL Check Oil Levels and Add as
* Procedure described separately Necessary
R Replace oil
 RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 27

BOGIES / STEERING LUBRICATION POINTS (LU2)

8
22
23

24

25

Kingpin Bearing /
Steering Lock

30
31

26

27, 28
5 5

6 7

3 4

Equipment Ref Item Procedure Quantity OK

Gantry Travel 4 Reduction gearbox * 0500-HOIL-01 8
O
Machinery 6000-R-01
5 Axle Bearings 1500-GG-03 8 x 2N O
6 Hub coupling spline 1500-GG-03 8 x 1N O
7 Hub "free- wheel" bearing 1500-GG-03 8 x 1N O
8 Kingpin bearings 1500-GG-03 8 x 1N O
3 Motor coupling 6000-RCG-11 8 O
Steering Lock 24 Locking pin 1500-GG-03 8 x 1N O
26 Locking pin limit switches * 1500-CAN-10 8x2 O
27 Absolute Encoder pinion 1500-CAN-10 8x1 O
22 Motor coupling * 6000-RCG-11 8 O
23 Reduction gearbox * 6000-RGG-03 8 x 1N O
28 Safety limit switch * 6000-GB-4A 8x1 O
25 Bushing 6000-GB-4A 8 O
Bogie Beam 30 Pivot Pin 1500-GG-03 4 x 4N O
31 "Cat's whisker" collision sw. * 1500-CAN-10 4 O
Procedure Definition: H-LP-LG LP. ID Lubricating Procedure
Description
H = Hour Interval (500-6000) GG Grease Gun Application
LP = Lubricating Procedure GB Grease Brush Application
LG = Lubricant Group RCG Replace Coupling Grease
RGG Replace Gear Grease
* Procedure described separately CAN Oil-Can Application
HOIL Check Oil Levels and Add as
Necessary
R Replace oil
 RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 28

HEAD BLOCK LUBRICATION POINTS (LU3)

5

Locking
Mechanism
(2 pcs)

Equipment Ref Item Procedure Quantity OK

Head Block 1 Pulley bearing (hoist rope) 1500-GG-03 4 x 1N O
2 Pulley bearing (aux. rope) * 1500-GG-03 4 x 1N O
3 Limit switch 1500-CAN-10 4 O
4 Locking device 1500-GG-03 4 O
5 Linkage joint 1500-CAN-10 4 x 2N O
Procedure Definition: H-LP-LG LP. ID Lubricating Procedure
Description
H = Hour Interval (500-6000) GG Grease Gun Application
LP = Lubricating Procedure CAN Oil-Can Application
LG = Lubricant Group

* Procedure described separately

 RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 29

GANTRY LUBRICATION POINTS (LU4)

30

30

11
31
12

Equipment Ref Item Procedure Quantity OK

Diesel-Alt. 1 Door hinges 1500-GG-03 4 x 2N O
Access 11 E-room door hinge 1500-GG-03 2N O
Platform 12 Liftable ladder [Link]. * 1500-CAN-10 1 O
Leg Frame 30 Structural joint pins 1500-GG-03 18 O
31 Structural joint pins 1500-GG-03 4 x 4N O
Procedure Definition: H-LP-LG LP. ID Lubricating Procedure
Description
H = Hour Interval (500-6000) GG Grease Gun Application
LP = Lubricating Procedure CAN Oil-Can Application
LG = Lubricant Group

* Procedure described separately

RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 30

READ THIS BEFORE LUBRICATING

WARNING ! To avoid accidents, the safety from moving
or rotating machinery must be ensured.
ALL OF THE RELEVANT MOTIONS AND
DRIVES MUST BE PREVENTED FROM
OPERATING BY ISOLATING THEIR
ELECTRICAL SUPPLIES.

GEAR BOX LUBRICATION (IN 1)

LUBRICATION METHODS
The purpose of lubrication is to form an oil film to prevent direct metal contact
where the teeth touch, to lubricate the bearings and to dissipate the heat
generated in the gear through the gear walls or oil radiator to the surrounding air.
The proper lubricant must be selected to fulfill these functions.
The rim speed of the gear wheel and the structure and size of the gear unit are
used to determine the method of lubrication.

Bath Bath lubrication is used when the peripheral speed is less than
lubrication 2.5 m/s. (500 fpm). For bath lubrication, the oil level is raised to
the level of the ball race in the bearings.
Grease Grease lubrication may be used for lubrication of the individual
lubrication bearings in the gear unit.
Warming of An oil warmer may be used if the temperature of the oil in the
the oil gear unit drops below the solidification point. A heating resistor
is placed in the oil reservoir of the gear unit.
Cooling of the A cooling system must be used if the oil temperature goes
oil above the allowable temperature. The cooling system may
consist of a water-based heat exchanger, an oil-cooler using
water or air, or a fan installed on the primary shaft.
- There is an oil level pane on the gear unit for checking the oil level.
- The oil recommendation plate on the gearbox specifies the proper lubricant for
the gear unit.
- Spare gears are delivered from the factory without oil.
- The corrosion inhibitor inside the gear unit does not need to be removed prior
to filling the gear with oil.
- The gear unit must always be filled with oil before the use.
Note! Take care of waste oil, it is hazardous waste.

OIL LEVEL CHECK

The sight glass oil level must be between the upper and lower markings on the
glass. If there are no markings, the level can be anywhere within the range of the
sight glass.
Beware that an oil meniscus can remain in the bottom of the sight glass, even
though the true oil level in the gearbox is much lower.
RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 31

OIL REPLACEMENT
The first oil change shall be performed after approximately 250 hours of operation
or after 1 month of use. During each oil change, flushing oil shall be used to flush
the gear, and the magnet plugs shall also be cleaned.
In normal conditions the oil shall be changed once a year. For gears operating
under harsh conditions, or small gear units with a low oil quantity, the oil may
have to be changed more often (i.e. every 6 months).
Oil in the large gear units may remain usable for a longer period, allowing oil
change intervals to be lengthened. Prior to lengthening the intervals, a reliable
expert (i.e. oil company) must check the oil condition regularly and determines the
oil change intervals based on the results.
The use of impure or contaminated oil will cause gear damage in a short time.
The use of low quality lubricants may also cause damage to the gear.
The gearbox oil must be changed using the following procedure :
1) Make sure that the drive to the gearbox is prevented from operating.
2) Place a suitable container below the gearbox drain plug.
3) Remove the drain plug and allow all of the oil to empty from the gearbox.
4) Replace and tighten the drain plug.
5) Remove the container and dispose of the old oil.
6) Remove the filling plug and re-fill the gearbox with the correct quantity of new
oil.
Make sure that the new oil is the correct type and grade for the
application. Do NOT use old or contaminated oil !
7) Check that the oil level is correct using the relevant procedure. If not, add
more oil as necessary.
8) Replace and tighten the filling plug.
9) Using a suitable rag, remove any oil residue from the bottom surface of the
gearbox casing around the drain plug.
10) Check that there is no oil leak from the drain plug.

GREASE GUN PROCEDURE

Using a grease gun, inject some grease of the correct type into the nipple until the
grease starts to exude from around the output shaft.
 RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 32

TABLE - GEAR BOX OIL QUANTITIES

Gearbox Oil Quantity Lubr. Safety Precautions
Location Group
Litres Gal.
Make sure that the trolley is at the
Hoist normal parking position.
50 13.2 1
(LU1-3)
Make sure that the hoist is not
supporting any load. The spreader
Trolley should be resting on the ground (or on
Traverse 5 1.3 1 the top of a container).
(LU1-32)
Prevent all of the crane drive motors
Auxiliary from operating by isolating the power
Winch (LU1- 5 1.3 1 supply to the drives. The
22) diesel- alternator should be stopped.

Gantry Prevent all of the crane drive motors

Travel 9 2.4 1 from operating by isolating the power
(LU2-4) (1 supply to the drives. The
diesel- alternator should be stopped.
Steering
Lock Grease Packed 3
(LU2-23) (2

1) Both axle bearings are grease lubricated and are fitted with grease nipples.
The primary shaft double seal is also grease lubricated, but this is packed for
life during the assembly of the gearbox.
2) These gearboxes are packed with lithium based EP grease and are each fitted
with a grease nipple. Follow the Grease Gun Procedure.

Note! Do not mix any mineral oil based grease in these gearboxes.

MOTOR BEARING LUBRICATION (IN 2)

The method of lubricant application depends on whether the plant item is fitted
with grease nipples or not.
Grease Gun Application – KONECRANES Lubricant Group 3 apply to
bearings with grease nipples.
Using a hand operated grease gun, inject some grease into each nipple until the
bearing or sliding surface is fully packed with grease. Clean grease will exude
from the seal, when the bearing is fully packed.
If there are no grease nipples fitted to a bearing, that item does not require routine
lubrication.
The grease in "lubricated for life" anti-friction bearings should be changed after
several years in service. In this case, the plant item should be dismantled and
fully overhauled. The bearings should be cleaned and re-packed with grease
during the re-assembly. This is not a routine procedure and documents from the
original bearing manufacturer should be referred before lubricating.
RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 33

HOIST MOTOR BEARING

Note the following when lubricating the hoist motor bearing:
- Lubrication must be done while motor is in hoist or lowering motion to prevent
grease from entering to the motor. Be careful with the turning hoist drum.
- Grease is injected to the bearing through the grease nipple. Required amount
is approx. 80 g. (2.8 oz.). This amount is enough to replace the old grease
with new one.
- After filling, the excessive grease will be discharged out of the bearing
through the opening in the bottom of the bearing construction.
- Open the hatch of the cover and wipe out the excessive grease from the
bottom of the motor coupling tube. Close the hatch.
- Remove the hoist motor fan carefully. Wipe out the excessoive grease inside
the fan housing. Reinstall the fan.
1. Grease valve disc
1 2 3 4 5 6 7
2. Outside bearing cover
3. End shield
4. Ball bearing
5. Grease nipple
6. Inside bearing cover
7. Felt sealing strip

BEARINGS IN OTHER MOTORS

Lubrication is necessary for gantry, ACM or trolley traverse ‘self lubricated motor
bearings’ after 25 000 hours of use.

LINKAGE & LIMIT SWITCH LUBRICATION (IN 3)

Oil can application - KONECRANES Lubricant Group 10 apply.
Using an oil can, apply a few drops of oil to the pivots and slides of each linkage.
Do not over lubricate the operating shafts of limit switches. Oil must not get onto
the electrical contacts.
RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 34

WIRE ROPE LUBRICATION (IN 4)

READ THIS FIRST

WARNING ! Before this lubrication procedure is started,
the spreader must be in the fully raised
position and must be empty (no attached
container).

LUBRICATING METHOD AND LUBRICANT TYPE

The four hoist ropes and the four auxiliary ropes must be fully lubricated over their
full length. This is necessary to prevent corrosion and to ensure that the steel wire
strands slide smoothly against each other when a rope bends around a pulley.
Lubricating grease type - KONECRANES Lubricant Group 4B apply.
The lubricating greases in this group are suitable for application using a brush.
As an alternative, special steel rope lubricating oils can also be used. These can
be applied with a brush or by using a spray.

ROPES AROUND EACH HOIST DRUM

Using a suitable brush, fully coat the turns of the two hoist ropes and the two
auxiliary ropes that are wound around each hoist drum.

HOIST ROPES FIXED END FITTINGS

Using a suitable brush, coat the fixed end of each hoist rope where it passes
through its wedged head fitting on the trolley.

AUXILIARY ROPES AROUND EACH AUXILIARY WINCH

DRUM
Using a suitable brush, fully coat the turns of the auxiliary rope that are wound
around each auxiliary winch drum.

SUSPENDED ROPES
1. Using a suitable brush with a long handle, fully coat the suspended lengths of
the two hoist ropes and the two auxiliary ropes between each hoist drum and
the spreader pulleys.
2. Using a suitable brush with a long handle, fully coat the suspended length of
the each hoist rope between the fixed attachment points on the trolley and the
spreader pulleys.
3. Using a suitable brush with a long handle, fully coat the suspended length of
the each auxiliary rope between its auxiliary winch drum and the spreader
pulleys.
Note! If the crane will not be used for some time, the hoist should be lowered
slightly so that lubricant can also be applied to the rope lengths that are
around the spreader pulleys.
RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 35

LUBRICATING COUPLINGS IN TROLLEY (IN 5)

READ THIS FIRST

WARNING ! Before this lubrication procedure is started,
the spreader must be resting on the ground
(or on the top of a container), with the hoist
ropes slack.

LUBRICATING METHOD AND LUBRICANT TYPE

Lubricating Grease Type - KONECRANES Lubricant Group 11 apply.
This is a special lithium based grease with molybdenum disulphide and EP
additives.
NOTE: DO NOT USE THE GENERAL EP GREASES FROM KONECRANES
LUBRICANT GROUP 3.

GREASE LUBRICATION PROCEDURE (EACH DRUM

COUPLING)
1. Remove the hexagon headed vent plug from
the hub of the coupling (near to the gearbox
output shaft).
2. Using a grease gun, inject some grease of the Vent Plug
correct type into the greasing nipple (at the
opposite side of the coupling), until clean
grease exudes from the vent hole.
3. Clean off any excess grease. Note! Do NOT forget the
4. Replace the vent plug replacement of the vent
plug.
- Add lubricant always when installing the coupling at the first time and after
every 1 month or 250 operating hours.
- Replace the lubricant completely always after inspection

GREASE LUBRICATION PROCEDURE (EACH MOTOR

COUPLING)
1. Remove the cover plate from the outside of the flanged mounting tube
between the hoist motor and the gearbox.
2. Using a grease gun, inject some grease of the correct type into the nipple on
the outer part of the motor coupling until the coupling is fully packed.
3. Clean off any excess grease from around the outside of the coupling.
4. At the same time check the free axial movement of the flanged sleeves ± 1.5
mm (± 1/16 inch).
5. Replace the cover plate on the outside of the flanged mounting tube.
RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 36

LUBRICATING COUPLINGS IN BOGIE (IN 6)

READ THIS FIRST

WARNING ! During this lubrication procedure, all drive
motors for the gantry travel motion and
steering lock must be prevented from
operating by isolating their power supplies.

COUPLING IN GANTRY TRAVEL MOTOR COUPLING IN STEERING

LOCK
The couplings between the gantry travel motors The couplings between the
and their gearboxes are not directly accessible steering lock motors and their
and hence they are not fitted with greasing gearboxes are not directly
nipples. To lubricate each coupling during the accessible and hence they are
annual routine maintenance, the gantry travel not fitted with greasing nipples.
motors must be partially removed. However, To lubricate each coupling
this can be done without disconnecting any during the annual routine
cables. maintenance, the steering lock
motors must be partially
PREPARATIONS
removed. This can be done
1. Before this lubrication procedure is started, without disconnecting any
the gantry travel mode should be selected to cables.
"Cross Travel" so that all gantry travel
motors are easily accessible. PREPARATIONS
2. The wheel chocks should be inserted under Before this lubrication procedure
all of the bogie wheels to prevent the gantry is started, the wheel chocks
from moving while the travel motors / brakes should be inserted under all of
are disconnected. the bogie wheels to prevent the
steering from moving while the
3. This procedure requires a jacking platform or steering lock motors / brakes
lifting frame to support the weight of a gantry are disconnected.
travel motor / brake assembly.

LUBRICATING METHOD AND LUBRICANT TYPE

Lubricating Grease Type - KONECRANES Lubricant Group 11 apply.

This is a special lithium based grease with molybdenum disulphide and EP

additives.
NOTE: DO NOT USE THE GENERAL EP GREASES IN KONECRANES
LUBRICANT GROUP 3.
RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 37

COUPLING DISMANTLING

GANTRY TRAVEL MOTOR PIVOT LOCKING MOTOR

1. Disconnect the supporting brackets 1. Remove the cover from the
for the flexible cables between the non- driven end of the motor.
gantry travel motor / brake and the 2. Slacken and remove the four long
bogie mounting structure.
fixing bolts between the steering
Do NOT slacken the cable clamps on lock motor and the gearbox flange.
the supporting brackets.
(These bolts pass through the full
2. Using a suitable jacking platform or length of the motor casing)
lifting frame, support the weight of the 3. Carefully withdraw the motor
gantry travel motor / brake assembly. upwards, until the coupling has
3. Slacken and remove the four fixing separated from either the motor or
bolts between the flange of the gantry the gearbox shaft.
travel motor and the gearbox.
4. Using a suitable lashing, temporarily
4. Carefully withdraw the motor axially, support the weight of the motor so
until the coupling has separated from that no strain is put on the flexible
either the motor or the gearbox shaft. cables.
5. Pull the coupling off the other 5. Pull the coupling off the other
shaft. shaft.

COUPLING CHECKING AND GREASING

1. Clean the old grease from inside the coupling and from the splines on the
motor and the gearbox shafts.
2. Check that non of the coupling or shaft splines are damaged or badly worn.
3. Check that the grease sealing O- rings are in good condition on the motor
shaft and on the gearbox shaft. Replace them, if necessary.
4. Using a spatula, thoroughly coat all of the splines inside the coupling with new
grease of the correct type.

COUPLING RE- ASSEMBLY

1. Make sure that the end of the coupling with the groove on the outside is
towards the gearbox input shaft. Refit the coupling onto the spline of the
gearbox input shaft.
2. Carefully align the motor shaft with the coupling and then slide the motor
shaft into the coupling. Minor adjustments of the motor position may be
necessary before the splines can be engaged.
3. Replace the four motor mounting bolts and tighten them to the correct
torque. Gantry motor 173 Nm (126 lb-ft) and steering lock motor 8.5 Nm
(6.3 lb-ft).
4. With gantry travel motor refit the supporting brackets for the flexible cables.
With steering lock motor replace the cover onto the none-driven end of the
motor.
RTG Maintenance Vol 2 – Preventive Maintenance – Lubrication 38

ENCODER/ LIMIT SWITCH GEAR LUBRICATION

(IN 7)

READ THIS FIRST

WARNING ! During these procedures, all trolley and gantry
motions, including the steering lock ,must be
prevented from operating by isolating their
power supplies.

NOTE: HOIST ENCODER / LIMIT SW. NOTE: BOGIE ENCODER / LIMIT SW.
The transmission gears of the position The transmission gears for the
encoder / limit switch assembly for each steering position encoder of each
hoist are not directly accessible. bogie is directly accessible and the
lubrication of these gears during the
To permit the lubrication of these gears
during the annual routine maintenance, annual routine maintenance can be
their protective cover must be removed. done without removing any protective
cover or disconnecting any cables.
This can be done without disconnecting
any cables.

LUBRICATING METHOD AND LUBRICANT TYPE

Lubricating Grease Type - KONECRANES Lubricant Group 4A

This is a special grease for open gear transmissions.

NOTE: DO NOT USE THE GENERAL EP GREASES FROM
KONECRANES LUBRICANT GROUP 3.

LUBRICATION PROCEDURE (EACH ENCODER/LIMIT SWITCH)

EACH HOIST ENCODER / LIMIT SWITCH EACH BOGIE POSITION ENCODER
1. Remove the protective cover from the 1. Using a suitable brush, coat the
top of the encoder / limit switch teeth of the gear wheel and the ring
assembly by undoing the six gear with the correct type of grease.
attachment screws (M6). 2. Remove any protective covers to
gain access to the sliding surfaces.
2. Using a suitable brush, coat the teeth
3. Completely coat all of the
of both gears with the correct type of
accessible parts of the sliding
grease.
surfaces with grease using a
3. Check that the flexible coupling (on suitable brush for application.
the shaft the position encoder) is in In certain cases, it may be
good condition. necessary to operate the plant item
4. Refit the protective cover. for a few times, to distribute the
grease between the sliding
surfaces. However, this should only
be done if there is no risk of an
accident.
4. Replace any protective covers.
 RTG Maintenance Vol 2 – Preventive Maintenance – Wire Rope Inspections 39

WIRE ROPE INSPECTIONS

WIRE ROPE INSPECTION REQUIREMENTS
The examination and discard of wire ropes for cranes is specified in ISO Standard
4309. This Code of Practice applies at all times and takes precedence over any
other inspection and discard procedure.
The following procedures are intended for guidance in meeting this Code of
Practice.

VISUAL INSPECTIONS FOR EACH ROPE

Before these rope inspections, the spreader should be lowered so that it is resting
on suitable blocks of wood at ground level (hoist ropes slack).

WARNING! To prevent accidents with moving or rotating

machinery, the supply to all motor drives must
then be isolated during the inspections.

Inspection Description Rope Type

Point Hoist Aux
General The visual inspection of the full length of each
Visual rope should be carried out in accordance with the X X
Inspection Inspection Requirements section.
End Clamps The ends of each rope should be inspected for
corrosion or damaged strands at the clamp
positions onto the corresponding drum. (Note: X X
Hoist and Aux. Winch drum with aux. rope)
End Fittings The ends of each hoist rope should be inspected
onto Trolley for corrosion or damaged strands at the end fitting X
positions onto the trolley.

BROKEN WIRES
A wire rope with round strands is permitted to have a number of broken wires,
before the rope must be discarded.

Rope Construction Maximum Number of Broken Wires Over Length

(Load Bearing Wires) 6 x Diameter 30 x Diameter
6 x 36 Ordinary Lay 7 14

Note: The wires in the steel core are not classed as "load bearing" and must be
discounted from this assessment.
 RTG Maintenance Vol 2 – Preventive Maintenance – Wire Rope Inspections 40

CORROSION
If a wire rope is corroded, the extent of the damage and hence the reduction in the
breaking strength cannot be easily determined.
When any wire rope shows visible signs of corrosion, it must be inspected by a
Competent Person.

ROPE DEFORMATION
There are several possible forms of rope deformation. When any of these is found
by visual inspection, the extent of the damage must be evaluated by a competent
person, before the Unloader is used again. The discard criteria must be applied
and any defective ropes must be replaced, before the Unloader is used again.

Waviness

To measure the waviness, lay the rope along a flat surface, and measure the
maximum height 'x' of the top strands of the rope above the surface.

If x > 4d , where d is the rope diameter, the rope must be discarded.

3

Basket or Lantern Distortion

A rope with basket or lantern distortion must be discarded.

Strand or Wire Extrusion

A rope with strand or wire extrusion must be discarded.

RTG Maintenance Vol 2 – Preventive Maintenance – Wire Rope Inspections 41

Local Increase in Diameter

A local increase in diameter can be caused by a failure of the internal core. If the
deformation is severe, the rope must be discarded.

Local Decrease in Diameter

A local decrease in diameter can be caused the disintegration of the internal core.
If the deformation is severe, the rope must be discarded.

Flattened Portions

Flattened portions are usually caused by mechanical damage from impact or

jamming. If the deformation is severe, the rope must be discarded.

Kinks or Tightened Loops

 RTG Maintenance Vol 2 – Preventive Maintenance – Wire Rope Inspections 42

A rope with a kink or tightened loop must be discarded.

Severe Bends

Severe bends are usually caused by external influence. The rope must be
discarded.

ROPE DIAMETER MEASUREMENTS

WARNING! To prevent accidents with moving or rotating
machinery, the supply to all motor drives must
be isolated during these tightness checks.

These procedures apply to hoist and auxiliary ropes. The diameter measurements
must be made at several positions along the length of the ropes. The highest
wear rates are likely to be on the parts of the ropes which pass most frequently
around the pulleys and onto the hoist drums.
It should be noted that for a laid rope, the diameter is defined as an imaginary
circle around the outside of all of the cores. The correct diameter measurement is
shown below in figure 1. The wrong diameter measurement in figure 2, gives a
false lower value.

OK! Not OK !

Fig. 1 - Correct Diameter Measurement Fig. 2 - Wrong Diameter Measurement

At each chosen position for the diameter check, the measurement should be
repeated across each of the three alternative pairs of strands. The average of
these three readings should be used in determining the correct rope diameter.
This allows for minor ovality in the rope.
RTG Maintenance Vol 2 – Preventive Maintenance – Wire Rope Inspections 43

Note!
For easy access to the ropes without the need for an access platform, the
spreader should be moved to different heights for each position measurement.
Check Height of an empty Rope Type
spreader
Hoist Aux
Diameter of each rope at the position Just above the ground
near to its hoist drum. level (Ropes in tension) X X
At mid height X X
Suspended at the fully
raised position X X
Diameter of each rope at the position near to its rope end fitting
which is attached onto the trolley. X
Diameter of each rope at the position near to its aux. winch drum. X
Note: The rope diameter data sheet is presented in the ‘Rope Change’
paragraph in ‘Special Procedures’ section later in this manual.

EXTERNAL WEAR
The outside diameter of a wire rope can be reduced by wear as it passes around
the pulleys or over plain guides. The diameter should be checked over any part of
the length where such abrasion can occur.
If the diameter is reduced by 7% or more, the rope must be discarded. This
applies, even if none of the wires are broken.

LOCAL DECREASE IN ELASTICITY

The maximum stresses in a rope usually occur close to the end fittings, where the
strands are prevented from moving relative to each other. Therefore, the rope
diameter measurements should also be taken near to the end fittings.
If the diameter is reduced by 7% or more, the rope must be discarded. This
applies, even if none of the wires are broken.

CLAMP TIGHTNESS CHECKS FOR EACH ROPE

WARNING! To prevent accidents with moving or rotating
machinery, the supply to all motor drives must
be isolated during these tightness checks.

Procedure Clamp Rope Type

Location Hoist Aux
The tightness of the clamps which attach each rope Hoist Drum X X
onto the corresponding drum must be checked.
Apply the correct bolt tightening torque to all of Aux. Winch
these clamps using a suitable torque wrench. Drum X
Note: The torque data sheet is presented in the ‘Rope Change’ paragraph in
‘Special Procedures’ section later in this manual.
RTG Maintenance Vol 2 – Preventive Maintenance – Wire Rope Inspections 44

WIRE ROPE INSPECTION PLAN

READ THIS BEFORE STARTING

WARNING ! To avoid accidents, the safety from moving or
rotating machinery must be ensured.
All of the relevant motions and drives must be
prevented from operating by isolating their
electrical supplies.

INSPECTION INTERVALS
Every Month The visual inspections for hoist and auxiliary ropes are carried out
or 250 hours as described earlier in this paragraph.
Every 3 The rope diameter check and the clamp tightness check for hoist
Months or and auxiliary ropes are carried out as described earlier in this
750 hours paragraph.

ROPE DEFECTS FOUND

It is important that any defects that are found during the routine inspections are
recorded and acted upon.
The rope replacement criteria are specified in ISO 4309 and are summarized in
the Inspection Requirements section.

HOIST ROPE DEFECTS

WARNING! If any hoist rope is corroded, damaged or worn so
that it does not meet the acceptance criteria in
ISO 4309, the continued operation of crane is
forbidden until the ropes have been replaced.
Note: The rope replacement procedure is presented in paragraph ‘C. Rope
Change’ in ‘Special Procedures’ section later in this manual.

AUXILIARY ROPE DEFECTS

Although the auxiliary ropes are not necessary for the safe lifting operations of the
crane, a damaged or broken auxiliary rope can snag in a hoist drum or in the
pulleys of the spreader head block.
If an auxiliary rope does not meet the acceptance criteria in ISO 4309, the
restricted operation of the crane is only permitted if the defective rope is removed
from the crane and the auxiliary winch system for sway suppression and fine
position movements is disabled.
This disabling procedure for the auxiliary winches and the replacement procedure
for the auxiliary ropes is given in section 4 in this manual.
 RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 45

HOIST BRAKE (BUBENZER)

SEE ANNEX1:
HU3.04.0061EN
BUBENZER DISK BRAKE
Operating Manual for Disk Brake
TYPE: SB-28
28-0598-01/4

HOIST BRAKE (PINTSCH-BAMAG)

READ THIS FIRST
WARNING ! - Read the general safety precautions at the
beginning of this manual.
- Special safety information is provided at the
beginning of a chapter or specific point in the
text.
- To avoid accidents, the safety from moving or
rotating machinery must be ensured.
- Lock off the supplies to all crane drives before
maintenance work is started.
- Before inspecting the brake make sure that the
shaft is prevented from rotating by isolating the
electrical power to the corresponding motors.
- During the maintenance work, do NOT release
the brake while there is any external torque
applied to the shaft.
Unusual In the event of unusual changes to the brake, power supply must
changes with be immediately be disconnected. Any unusual changes, e,g.
brakes development of smell at the brake, must immediately be reported
to the person concerned or the customer service department
notified in order to prevent the brake suffering further damage.
Before Any Before starting any maintenance work, lower the spreader on the
Maintenance ground and slacken the ropes. This way the torque is removed
Work from the hoist brake shaft.
 RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 46

The brake for each hoist is on the input shaft

Stepped End Flange
of the reduction gearbox, at the opposite end
to the drive motor.
Each brake has one rotating disc with friction
Friction Disk linings on either side. There is a spline
between hub of the brake and the extension
Armature Plate of the gearbox shaft.
The brake is engaged by multiple springs
Solenoid Coil
which force the armature plate against the
disc. This armature plate is prevented from
rotating by pins which are on the same
circumference as the springs.
The brake is released by a solenoid, with the
coil embedded inside part of the brake body.
When this solenoid is energized, the
armature is attracted towards the solenoid
coil with a force which exceeds that of the
brake engaging springs.
Air Gap
When the brake is engaged, there is a small
air gap between the solenoid housing and
the armature. As the friction linings wear, this
air gap increases. If the air gap becomes too
large, the solenoid may be unable to attract
Access Plug the armature with sufficient force to release
the brake.

OVERVIEW
Cover Plugs for Manual Release Bolts
Plug for Air gap Measurement

Housing
Brake Mounting flange
Rating plate

Condensation Water Drain Plug

RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 47

Brake rating plate

Brake designation
Brake torque

Factory set air gap

Maximum air gap
Brake serial number

BOLT AND NUT TIGHTENING TORQUES

Bolt or Tightening torque Bolt or Nut Tightening torque MA (Nm

Nut Size MA (Nm) Size
8.8 10.9 8.8 10.9
M8 25 36 M18 300 430
M10 49 72 M20 425 610
M12 85 125 M22 580 830
M14 135 200 M24 730 1050
M16 210 310
Bolt and hexagon socket screw key size for manual release bolts are
as follows:
- M12 for Manual release bolts DIN 912 self-locking
- Key size 10 for hex. socket screw key DIN 911
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 48

Cap nut
Sealing ring
Housing

O-ring

Lock nuts

Brake flange

Friction plate assembly

Manual release bolts

Armature plate

Stud bolt (with stepped shank)

Springs

Coil body assembly with brake mounting

flange

Stud bolts
Cable from solenoid coil
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 49

INSTALLING THE HOIST BRAKE

READ THIS FIRST

WARNING ! Prior to fitting the brake, the following
safety information must be observed:

Shutdown RTG To avoid accidents, the safety from moving or rotating

prior to fitting brake machinery must be ensured.
ALL OF THE RELEVANT MOTIONS AND DRIVES
MUST BE PREVENTED FROM OPERATING BY
ISOLATING THEIR ELECTRICAL SUPPLIES.
Make sure that RTG is secured to prevent accidental
activation of power supply.
Electromagnetic In the immediate distance of hoist brake electromagnetic
Fields fields can be produced.
Persons with pace-makers or implants must avoid the
area of hoist brake in any event. The strong
electromagnetic fields pose a danger to life!
No objects must be placed or left lying around in that
area. This applies in particular to metal object.
Do not use any The brake is designed for dry-running operation. For this
grease reason, no greases or oils must be used during
installation of the brake. Greases and oils reduce the
braking action. The hub in particular must not be oiled or
greased.
Danger of crushing When carrying out work on the brake, heavy tools are
used. Particular attention should therefor be paid to
possible crushing points when:
- Using tools
- Fitting and removing the brake, accessories or
spare parts
- Unbolting the brake from the pallet
Use lifting The brake weighs 242 kg (540 lbp). For brake
equipment installation purposes, lifting gear or another crane can be
used.

Protection of inner Dirt, oil and spray water reduce the braking capacity.
brake The friction linings, brake flange and armature plate
must be protected when the brake is open.
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 50

Hoist Brake Fitting

Brake Motor The brake must be prepared for fitting
according to the following procedure:
- Remove cap nuts and sealing
rings
- Remove housing
- Simultaneously tighten manual
release bolts evenly clockwise,
so that the friction plate
assembly moves freely within
the brake housing

Brake flange
Manual release bolts

Armature plate
Air gap

Coil body + mounting flange assembly

Friction plate

− Check that the friction plate moves freely

If the friction plate does not move freely:
− Simultaneously further tighten manual release bolts carefully and evenly
clockwise
Prior to fitting the brake:
− Fit hub fully on the motor shaft
Key

Motor shaft

Hub
− Secure the hub axially on the motor shaft with a bolt and washer or circlip.
− With suitable lifting gear, lift the brake so that the mounting flange and brake
can be cleaned and sealing compound applied, e.g. CURIL K2.
− Subsequently clean the motor flange and apply sealing compound.
− Lift the brake with suitable lifting gear and carefully position the teeth of the
friction plate over the teeth of the hub.
 RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 51

− Feed the connecting cable throught the opening in the mounting flange as
shown in the illustration.
− Have electrical connections made by a qualifield electrician.

WARNING ! Also observe the safety information in the

chapter “Electrical connection”

Connecting cable and opening in

brake mounting flange

− After electrical connection, bolt the brake mounting flange to the motor flange.

Observe bolt The prescribed tightening torque must be observed when

tightening torque tightening bolts (see “Technical Data”).
Simultaneously unscrew both manual release bolts evenly
counter-clockwise until the heads just make contact with the
brake flange.
Do not unscrew The manual release bolts are held captive by the brake
manual release flange after they have been released from the armature
bolts with force plate. If the manual release bolts are unscrewed with force
over and beyond the resistance, the brake can be damaged.
Ensure correct A check should be made to ensure that the manual release
braking action bolts are unscrewed properly. If the manual release bolts
are tightened, the brake will not operate or be restricted.

Remove foreign When fitting the housing, the housing O-ring and contact
bodies on O-ring surfaces must be free from foreign bodies, otherwise the
and surfaces. housing will not provide a proper seal.
Clean O-ring and contact surface.
Fit the housing noting the installation position, the mark on
the housing must correspond with the mark on the adapter
flange
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 52

Marks (notches)

Brake adapter flange

Housing

ELECTRICAL CONNECTION

READ THIS FIRST

WARNING ! Prior to fitting the brake, the following safety
information must be observed:

Only qualified Only a qualified electrician may connect the brake to the DC
electrician supply and check the current flow, taking into all safety
measures. Incorrect connection may have fatal consequences!

Earthing The brake must be earthed in compliance with the applicable

regulations.

Shutdown To avoid accidents, the safety from moving or rotating

RTG prior to machinery must be ensured.
fitting brake ALL OF THE RELEVANT MOTIONS AND DRIVES MUST BE
PREVENTED FROM OPERATING BY ISOLATING THEIR
ELECTRICAL SUPPLIES.
Make sure that RTG is secured to prevent accidental activation
of power supply.
Provide Brakes with a coil output of 100 W and higher must be
overvoltage provided with overvoltage protection to prevent damage to the
protection coil on disconnection of the brake power supply.
Prevent brake To prevent the brake overheating, it must be ensured that the
overheating motor to be braked does not continue to run in the event of an
undesired power failure.
Do not switch − Disconnect the power supply to the motor before
on connecting the brake
− Provide a “Do not switch on” sign at the switching point
− Establish electrical connection
− Remove the sign
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 53

COMMISSIONING THE BRAKE

READ THIS FIRST

WARNING ! Prior to commissioning the brake, the following
safety information must be observed:

Overloading the The operator is obliged to adjust the motor for the brake in
brake such a way that the brake cannot be overloaded. Overloading
the brake would cause heavy brake lining wear.
Note: As a result of chemical degreasing at the factory, the
armature plate and brake flange may have a bluish
discoloration; this is not an indication of thermal
overload
Risk of burns! During operation, the brake can reach temperatures up to
80oC (176 F). Any contact with the hot brake housing must
therefore be avoided
Maintain In order to prevent damage to the brake, the brake must be
maximum operated also during commissioning only within the
speed range permissible speed range.
Note: Loading case and technical data sheets must be
observed
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 54

FUNCTION CHECK

READ THIS FIRST

WARNING ! A function check must be carried out
prior to each initital use. Observe the
following safety information before
carrying out the function check:

Do not place or Remove all metal or flammable objects from the working
leaving area of the brake.
anything lying
around in this
area
Do not reach If the function check is carried out with the housing
into rotating removed, reaching into rotating brake must be avoided
brake in any event.

Seal replacement
All seals removed for the function check must be replaced with new seals.
• With the housing removed, connect and disconnect the brake power
supply several times The armature plate moves during switching
between the coil body group and friction lining group.
Airgap Armature plate
Friction lining group

Brake flange

Coil body group

After completing function check:

• The procedure for cleaning and fitting the housing is as described in the
chapter “Installation” under the section “Fitting the brake”.

CHECKING THE AIRGAP

To ensure correct operation of the brake, the airgap between the coil body
group and armature plate must have the prescribed size. The minimum or
maximum airgap is shown on the brake rating plate. The brake is set with
the minimum airgap at the factory.
Check the airgap through the open tapped holes at three points:
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 55

Bolt with sealing ring

• Unscrew bolts with sealing rings from the housing

• Insert feeler gauge through the open tapped holes at all three points
• Measure the airgap between the armature plate and coil body group.
• Re-insert bolts with sealing rings and tighten. Old sealing rings cannot
prevent the ingress of water.

CONNECTION OF THE POWER SUPPLY

On connection of the brake power supply, an electromagnetic field builds up.
This causes the armature plate to be drawn towards the coil body group and
the brake is released. The friction lining group of the brake can now rotate
freely between the armature plate and brake flange.

DISCONNECTON OF THE POWER SUPPLY

On disconnection of the brake power supply, the electrmagnetic field
collapses and the brake is applied.
The pressure of the springs forces the armature plate againts the friction
lining group. The friction lining group simultaneously presses againts the
brake flange.
The mechanical friction is transferred to the motor shaft via the friction lining
plate and driving hub. The motor is braked.

WARNING ! An overvoltage protection must be

provided to prevent damage to the coil on
disconnection of the brake power supply.

RUNNING-IN FRICTION LININGS

With the commissioning of the brake or after renewal of the friction lining
group, the friction linings must be run-in. Only when this has been done is
the specifield braking torque fully transmitted.
Several controlled braking operations should be carried out, bearing in mind
that the full braking power is not initially available. Braking under full load
must be avoided.
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 56

BRAKE OPERATION
WARNING ! The following safety information must be
observed for operation of the brake:

Unusual changes
In the event of any unusual changes to the brake, the brake power supply
must immediately be disconncted. Any unusual changes , e.g. the
development of smell at the brake, should immediately be reported to the
person concerned or the customer service department notified in order to
prevent the brake suffering further damage.

WARNING ! An overvoltage protection must be provided

to prevent damage to the coil on
disconnection of the brake power supply.

Permissible braking energy

The permissible braking energy can be determined from the thermal load
diagram.
Braking speed n = 1500 rpm

Braking operation per hour z [1/h]

 RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 57

With a known switching energy per braking operation and number of

braking operations per hour, the brake size can be determined.
Example: Q=100kJ/switching energy and z=35 braking operations/hour
=brake SFB 100.

MANUAL RELEASE

READ THIS FIRST

WARNING ! The following safety information must be
observed before releasing the brake
manually:

Manual release Under no circumstances must the manual release be used

only for for the purpose of maintaining temporary operation. It is
emergencies intended for emergency use only.

Disconnect It must be ensured when releasing the brake manually that

Power Supply the power supply to the brake remains disconnected and
cannot be accidentally reconnected.
Note position of It is important to note the position of the load when releasing
load the brake manually and that the surrounding area is cleared
before the load is lowered.
High brake Depending on the operaing mode, the brake can reach high
temperature temperatures. It may therefore be necessary to wear
protective gloves when releasing the brake manually.
Contact with a hot brake when releasing the brake manually
must be avoided as burns can result.
Releasing the brake manually means briefly releasing the brake by manual
actions and only in an emergency, e.g. in order to lower suspended loads
carefully.
The housing can remain fitted when releasing the brake manually.
• Unscrew lock bolts with seals on the front of the housing. Figure 1

Lock bolts Manual release

rating
to
according
Airgap
plate
 RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 58

Figure 1 Figure 2

Brake released
Airgap 0 mm

Figure 3
• Simultaneously turn both manual release bolts evenly clockwise. Figures 2
and 3 The armature plate is now drawn slowly towards the coil body group
against spring pressure and the brake is released. Any suspended load should
be observed when releasing the brake.
• Carefully lower the load with the aid of the manual release bolts. The speed at
which the load is lowered can be accelerated by turning the bolts clockwise
and decelerated by turning counter-clockwise.
• Set down the load.
Airgap according to rating plate

Brake applied

Figure 4

CANCELLING MANUAL RELEASE

• Simultaneously loosen the manual release bolts evenly counter-clockwise and
unscrew until the bolt heads just make contact with the brake flange. Figure 4
• Refit the lock bolts with new seals.

READY TO OPERATE CONDITION

After setting down the load, the brake must immediately be restored to a ready to
operate condition.
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 59

Note: The brake is only ready to operate when the manual release bolts have bee
nturned back to their original position. Figure 4

HOIST BRAKE INSPECTION AND MAINTENANCE

READ THIS FIRST

WARNING ! Brake maintenance must be carried out
in strict observance of the safety
information provided here:

Danger to life Incorrectly maintained brakes can be dangerous. For

through incorrect this reason, only trained personnel may open and
maintenance maintain the brake.
Disconnect power Before carrying out any maintenance work on the brake,
supply the power supply must be disconnected and the
appropriate sign provided at the switching point.

Danger of crushing When working on the brake, heavy tools are used.
Particular attention should therefore be paid to possible
crushing points:
- Using tools
- Fitting and removing the brake, accessoriesor
spare parts
- Unbolting the brake from the pallet
Only qualified Only a qualified electrician may replace electrical
electrician components such as coil bodies, contactors. For safety
reasons, no description for the replacement of these
parts is provided in these operating instructions.
Use lifting equipment The brake’s weight is 242 kg (534 lb). For maintenance
purposes, lifting gear or another crane shall be used.
Do not use a crane Under no circumstances should the crane whose brakes
being maintained are being maintained be used for lifting purposes.
Active On completion of maintenance work, all tools must
electromagnetic initially be removed from the working area of the brake.
fields On connection of the brake power supply, the
electromagnetic fields of the brake become active.
Maintenance shall be limited to:
- Airgap check
- Brake flange reversal
- Friction lining group replacement
- Brake flange and armature plate replacement
- Condensation water drainage
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 60

CHECKING THE AIRGAP

Regular airgap checks are an integral part of maintenance routines. The
inspection intervals vary depending on the use of the brake. Weekly
inspection will ensure perfection functioning of the brake with average use.
See ‘Commissioning’ earlier in this chapter.
If the airgap should exceed the specified maximum airgap, the brake flange
must be reserved or the friction lining group replaced.

CONDENSATION WATER DRAINAGE

The condensation water must be drained from the brake once a year.
Depending on the climatic conditions in which the brake is operated, more
frequent drainage of the condensation water may be necessary. The
maintenance interval for a specific place of use should be determited by
draining the condensation water on a trial basis.

- Unscrew condensation water drain plug

and remove the seal.
- The condensation water can be drained
from the plug located below.
- New seals must be fitted after draining the
condensation water.
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 61

HOIST BRAKE CLEANING

Following extended operating times, abrasive dust can collect inside the brake
assembly. No particular maintenance is necessary. It is recommended to clean
the inside of the brake assembly as part of other maintenance routines.

READ THIS FIRST

WARNING ! Brake maintenance must be carried
out in strict observance of the safety
information provided here:

Disconnect power Prior to cleaning the brake, the power supply must be
supply disconnected and a warning sing provided at the
switching point.
Wear protective Protective goggles should be worn blowing out the brake
goggles to prevent abrasive dust going into the eyes.
Do not use any Do not use any corrosive chmicals for cleaning the
corrosive chemicals armature plate and brake flange. Only use grease
dissolving cleaning agents and suitable cleaning
materials.
Danger of crushing When cleaning the brake, heavy tools are used.
Particular attention should be paid to possible crushing
points when:
- Using tools
- Fitting and removing the brake, accessories or
spare parts
For blowing out the brake:
− Disconnect power supply.
− Unscrew cap nuts and seals on the front of the housing and remove the
housing.
− Blow out brake.
− Remove foreign bodies on O-ring and contact surfaces.
When fitting the housing, the O-ring of the housing or contact suface must be
free from foreign bodies.
For cleaning and fitting the housing, proceed as described in the chapter
“Installation” under the section “Fitting the brake”.
Subsequently check the airgap as described in the chapter “Maintenance”.
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 62

BRAKE FLANGE RESERVAL

READ THIS FIRST

WARNING ! Prior to fitting the brake the safety
information at the beginning of the
maintenance chapter must be observed.
Also the following safety information must be
observed:
Observe max.
airgap !
Right priority ! Under no circumstances must brake flange reserval take
place before the maximum airgap is reached.
Note: The brake flange can only be reserved once! The friction lining group
must subsequently be replaced and refitted.
When the maximum airgap is reached, the brake flange can be reserved:
− Disconnect the power supply.
− Remove cap nuts and sealing rings on housing and remove the housing.
− Simultaneously tighten manual release bolts evenly clockwise with hexagon
socket screw keys (DIN 911).
The friction lining group can now move treely.
− Unscrew hexagon nuts.
− Remove brake flange and clean as described in the chapter “Cleaning”.
− Reserve brake flange and fit with the “new” side facting the armature plate.

Before brake flange reversal : After brake flange reversal :

Maximum-airgap exceeded Airgap according to rating plate

Attention
The brake components are provided with small notches for marking purposes.
The notches must be located one on top of the other in a line. Failure to observe
this will result in brake malfunction or failure.
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 63

Brake flange
Friction lining group
Armature plate
Coil body group

− Tighten hexagon nut. When tightening the hexagon nuts, the tightening torque
must be observed.
− Simultaneously loosen ,annual release bolts evenly counter-clockwise until the
bolt heads just make contact with the brake flange.
− Remove foreign bodies on O-ring and contact surfaces. When fitting the
housing, the O-ring of the housing or the contact surface must be free from
foreign bodies.
− For cleaning and fitting the housing, proceed as described in the chapter
“Installation”.
− Subsequently check the airgap as described at the beginning of the chapter.
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 64

BRAKE FLANGE, FRICTION LINING GROUP AND

ARMATURE PLATE REPLACEMENT

READ THIS FIRST

WARNING ! Prior to replacement, the safety
information at the beginning of the
maintenance chapter must be observed.

Friction lining Friction lining group consists of:

group - Friction lining plate
- Friction lining
When to replace? Frcition lining group is subject to wear due to braking
operations and must be replaced when worn. The
replacement time depends on the braking frequency.
Replacement is also necessary if the friction lining group
has come into contact with oil, grease or similar.
Brake flange and Like the friction lining group, both these components are
armature plate subject to wear. It is recommended to also replace the
brake flange and armature plate with each second
replacement of the friction lining group. Further use will
reduce the life of the new friction linings.
Procedure for the - Disconnect power supply.
replacement of all - Remove housing.
three groups.
- Simultaneously tighten manual release bolts evenly
cllockwise. The fiction lining group now moves freely.
- Unscrew hexagon nuts on brake flange.
Only for brake - Remove brake flange and replace. Dispose of old
flange replacement brake flange.
Only for friction - Remove brake flange and clean as described in the
lining group and chapter “Cleaning”.
replacement: - Remove friction lining group and replacement.
Following replacement, the cooling ribs of the friction
lining group must point towards the brake flange.

Cooling ribs

Only for friction After fitting the fiction lining group, the brake flange with
lining group the initially side can be fitted as described in the section
replacement “Brake flange reversal”. The marks on the brake flange
must correspond with those of the other brake
components.
Only for Stand at the side of the brake
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 65

replacement of all When replacing the armature plate, the full spring
three components pressure of the brake is exerted. If the work is not carried
out correctly, parts of the brake can loosen throuth the
spring pressure and cause injury. It is therefore important
to stand at the stand of the brake when the following work
is carried out:
- Loosen manual release bolts evenly and remove.
- Remove armature plate and replace. When changing
the armature plate, it must be ensured that the
pressure spring do not fall out of the coil body group.
- Fit new armature plate with the recess facing the coil
body group.
- Provided on one side of the armature plate is a
recess. The side with the recess must face the coil
body group (see illustration).
This side must face - Recess.
the coil body group
To be noted for The marks on the components must be in one line, as
installation described in the chapter “Maintenance”.
- Fit new brake flange and tighten with hexagon nuts.
- The mark on the brake flange must corresbond with
those on the other brake components.
- Simultaneously unscrew manual release bolts evenly
counter-clockwise until the bolt heads just make
contact with the brake flange.
Remove foreign When fitting the housing, the O-ring of the housing or
bodies on O-ring contact surface must be free from foreign bodies.
and contact - For cleaning and fitting the housing, proceed as
surfaces described in the chapter “Installation” under the section
“Fitting the brake”.
- Subsequently check the airgap as described at the
beginning of the chapter.
Following replacement of the friction lining group, the
brake must be prepared for normal operation as
described in the chapter “Commissioning”.
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 66

HOIST BRAKE REMOVAL

READ THIS FIRST

WARNING ! Brake removel must be carried out in
strict observance of the safety information
provided here:

Danger to life Incorrect brake removal can be dangerous. Only trained

through incorrect personnel may therefore open and remove the brake.
brake removal

Disconnect power Before carrying out any work on the brake, the power
supply supply must be disconnected and a warning sign
provided at the switching point. It must also be ensured
that power cannot accidentally be connected while
working on the brake.
Danger of crushing When carrying out work on the brake, heavy tools are
used. Particular attention must therefore be paid to
possible crushing points when:
- Using tools
- Fitting and removing the brake, accessories or
spare parts
- Unbolting the brake from the pallet
Lifting equipment The brake weighs approx. 140 kg (309 lbp) and lifting
gear should be used for maintenance purposes.

Do not use the crane Under no circumstances must the crane whose brake is
on which the brake being removed be used for lifting brake components.
is being removed for
lfting purposes
For removal of the complete brake, the procedure is in reverse to that described
in the chapter “Installation”. Disconnection of the electrical connections must be
carried out only by a qualified electrician.
 RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 67

GANTRY, TROLLEY TRAVERSE AND

AUXILIARY WINCH BRAKE
STRUCTURE AND FUNCTIONAL DESCRIPTION
Generally the arrangement of the gantry, trolley traverse and auxiliary winch
brakes is similar to each other, although the component sizes of brakes are
different.
Each motor is fitted with an integral disc brake, on the non- driving end of the
motor shaft.
Lenze spring-loaded brakes are fail-safe brakes with 2 friction surfaces. Braking
torque is adjustable by means of a torque adjuster giving an even spring force.
The brake is released electromagnetically.

(N.A.)

The drawing above shows the brake in the de-energized state, i.e. with brake
engaged. The compression springs (4) press the armature plate (2) axially against
the rotor (6) which in turn is pushed against the other friction surface A-B. When
the coil is energized with D.C. current, the armature plate (2) is attracted to the
coil body (1). The armature plate (2) moves axially towards the fixed coil body
(stator), airgap "a" becomes zero and the rotor (6) is free to move.
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 68

BRAKE STRUCTURE
The brake includes the following main components: The complete coil body
comprising the coil (1), cylindrical compression springs (4), tappets (5), torque
adjusting rings (3) and armature plate (2). The rotor (6) is of non-magnetic
material with low inertia. It is provided with friction surfaces (6a) on both sides.
The splined hub (7) allows axial movement of the rotor.
The brake is fixed to the counter surface (mounting flange, bearing flange of
motor, etc.) by 3 or 6 hexagon socket screws. The distance of the coil body is
corrected by means of the adjustment tubes (8).

BRAKE CODING
NM34006ANR3 Type number
50 Nm-220V Braking torgue and connection voltage
95.42 Year- and week of manufacturing

Connection voltage [V]:

NR1 = 170, NR2 = 190, NR3 = 220, NR4 = 290, NR5 = 100

ELECTRICAL CONNECTIONS
The brake requires D.C. current to operate. The following supply arrangements
can be used, depending on the application.
Rectifier + brake

Transformer + rectifier + brake

The primary winding of the transformer is equipped with different inputs
depending on the voltage used. The secondary has always an output of ~220 V
which is rectified with bridge rectifier.

Transformer: AC voltage range [V]:

NM303NR1 220-480 (inputs: 220, 240, 380, 415, 440, 460, 480)
NM303NR2 500-600 (inputs: 500, 525, 530, 575, 600)
NM303NR3 208, 340, 356
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 69

MANUAL HAND RELEASE

The brake can be released mechanically by
means of the hand-release e.g. during a power
failure. The hand-release pulls the armature
plate towards the coil body allowing the rotor to
move freely i.e. releasing the brake.

INSPECTING BRAKES (ACM, TROLLEY, GANTRY)

READ THIS FIRST

WARNING ! - Read the general safety precautions at the
beginning of this manual.
- Read the safety precautions at the beginning
of this ‘Brakes’ chapter.

AIR GAP MEASUREMENT PROCEDURE

In normal applications, the brake requires no maintenance. The airgap "a" must
be checked and adjusted at certain intervals only in applications where the brake
is heavily worked . See adjusting values for the RTG Brakes in the Data Sheet at
the end of this chapter.
1. Remove the outer cover from the brake assembly end of the motor.
2. Using a set of feeler gauges, measure the air gap clearance between the body
of the solenoid coil and the armature.
If the air gap has increased to greater than the maximum value in the data table,
the air gap must be re-set to the correct value after first inspecting the condition of
the friction disc.
RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 70

LINING THICKNESS MEASUREMENT

1. By visual inspection, check that the thickness of each friction lining on
either side of the disc is approximately the same.
If not, the hub of the friction disc may be seized on the shaft spline.

2. Using a suitable external calliper, measure the distance between the

armature plate and the fixed backing plate to give the thickness of the
friction disc, including its linings.
If this is less than the minimum value in the data table, the friction disc
must be replaced by a new one.

3. Replace the outer cover when the inspections are completed.

BRAKE INSTALLATION
1. If no friction surface is available for use, fasten the mounting flange.
2. Push the rotor onto the shaft
3. In gantry brake the splined hub must be installed first on the shaft. After that the
rotor can be pushed onto the hub.
4. Place the screws equipped with spring washers through the fixing holes
provided in the coil body and screw into the friction surface. Remove the
screws preventing the adjustment tubes from opening during transport.
5. Check the airgap "a" between the armature plate and the coil body with a feeler
gauge at three different points around the frame.
6. To adjust the airgap, proceed as follows: Loosen the fixing screws, rotate the
adjustment tubes with an open-end spanner so that they move towards
the coil body, then tighten the fixing screws. The airgap should now be re
checked in accordance with section above.
7. Complete the electrical connections.
8. Install a dust seal, if required.
9. Install the fan and fan cover.

NOTE: The friction surface should never come into contact with any oil.
 RTG Maintenance Vol 2 – Preventive Maintenance – Brakes 71

ADJUSTMENT OF BRAKING TORQUE

The brakes are delivered pre-set to the torques shown in table above.
The torque adjuster can be unscrewed with a "C" spanner as far as the maximum
dimension "e".
The torque adjuster has a step action and one step changes the torque as shown
in the table “Red.” = Torque reduction (Nm/step).

TABLE - BRAKE DATA

Brake Type Torque Air Gap Disc+friction
linings min.
thickness
e Red. Braking Minimum Maximum
mm Nm Nm ft/lbs mm inch mm inch mm inch

Standard hoist speed (26/52 m/s or 85/170 fpm), 40 LT, 100kW motor
Hoist brake
Pintsch Bamag - - 1600 1180 0.40 0.016 2.40 0.094 - -
SFB160

Higher hoist speed (optional, 30/60 m/s or 100/200 fpm), 50 LT, 160 kW motor
Hoist brake
Pintsch Bamag - - 2100 1550 0.40 0.016 2.40 0.094 - -
SFB 160

Standard trolley traverse speed (70 m/s or 230 fpm)

Trolley trav. brake
Lenze NM34006A 11.5 1.5 50 37 0.30 0.012 0.80 0.031 6.00 0.236
NR3
Auxiliary winch
brake 10 1.2 25 18 0.30 0.012 0.80 0.031 6.00 0.236
Lenze NM34005A

Higher trolley traverse speed (Optional, 76 m/s or 239 fpm)

Trolley trav. brake
11.5 2.1 70 51 0.30 0.012 0.80 0.031 6.00 0.236
Lenze NM34007A
Auxiliary winch
brake 11.5 1.5 40 29 0.30 0.012 0.80 0.031 6.00 0.236
Lenze NM34006A

Gantry travel
Gantry travel brake
13 1.4 125 92 0.50 0.020 1.00 0.039 13.00 0.512
Lenze NM34008
 RTG Maintenance Vol 2 – Preventive Maintenance – Motors 73

MOTORS
READ THIS FIRST
WARNING ! - Read the general safety precautions at the
beginning of this manual.
- Special safety information is provided at the
beginning of a chapter or specific point in the
text.
- To avoid accidents, the safety from moving or
rotating machinery must be ensured.
- Do not wear garments with loose sleeves or
accessory which might get entangled with the
mechanical parts.
- Lock off the supplies to all crane drives before
maintenance work is started.
- Before inspecting or servicing the motor make
sure that the shaft is prevented from rotating by
locking it and isolating the electrical power to the
corresponding motors.
- During the maintenance work, do NOT remove
the motor while there is any external torque
applied to the shaft.
Unusual In the event of unusual changes to the motor, power supply must
changes be immediately be disconnected. Any unusual changes, e,g.
with motors unnormal vibration or noise must immediately be reported to the
person concerned or the customer service department notified in
order to prevent the mtor suffering further damage.
 RTG Maintenance Vol 2 – Preventive Maintenance – Motors 74

INSPECTION AND MAINTENANCE

The squirrel cage motors used in Konecranes cranes are completely enclosed
motors. Some motors contain one or two plugged drain holes. These holes are
located at the lowest points of the frame. The stator frame and bearing shields are
made of cast iron or aluminum alloy.
Check the following items:
1. Overheating (cleanliness, ventilation).
2. Operating noise
3. Vibration.
If there is exceptional vibration, the cause must be determined.
4. Mountings.
5. Drain holes. Check that the drain holes are free of dirt.
6. Condition of bearings.

Check the condition of the bearings by listening to them ie. by means of a

rod. An even humming sound indicates that the bearing is working
satisfactorily. If a distinct rattling is heard, the bearing is damaged and must
be replaced immediately. If the rattling sound is moderate and occasional, it
may be due to impurities or abrasive particles. In this case, either clean the
bearing or, if there is a lubricating valve in the bearing, change the
lubrication. After lubrication there may be an occasional cracking sound
from the bearing. The sound is caused by the excessive grease. It will soon
diminish.

INSULATION RESISTANCE
The most convenient method of evaluating the condition of the insulation is to
measure the insulation resistance. When the winding is clean and dry, the
insulation resistance is high. A low insulation resistance value is usually the
result of dampness or dirt.
The stator winding may be damp due to transportation conditions or storage of
the motor in a cold, damp or poorly ventilated location for a long period of time.
Therefore, the condition of the insulation must be checked prior to installation.
Measure the insulation resistance with a 1000 V mega-ohm meter. Take the
reading when the test voltage of the meter has been connected to the winding
for approximately one minute.
The insulation resistance for a cool winding (10 to 40°C or 50 to 104 F) should
be at least 5 MΩ. The insulation resistance for a warm winding (over 40°C
or 50 F) should be at least 1 MΩ. If the insulation resistance is lower, the motor
must be dried out.
The drying process is controlled by heat and ventilation. Drying may be
controlled in the following manner:
Use a heater fan to blow hot air (approximately 100°C or 212 F) onto the
windings inside the motor.
The windings may be dried in an oven at a temperature of approx. 100 °C or
212 F provided that there is reasonable ventilation. If the temperature is
increased slowly, the evaporation of the moisture will not damage the windings.
 RTG Maintenance Vol 2 – Preventive Maintenance – Motors 75

Initially, as the temperature of the damp winding begins to increase, the

insulation resistance will decrease. However, as drying continues, the
resistance will begin to increase. The drying may be stopped when the
resistance no longer changes.
If the winding is dry and the insulation resistance is still too low, the winding is
dirty or damaged. A dusty winding may be cleaned carefully. The winding may
only be washed by a specialist.

EXCEPTIONAL VIBRATION
If there is exceptional vibration in the motor, the cause must be determined ie.
as follows:
1. Dismount the motor from the driven machinery. Start the motor while it is
on the bed plate and lift it by means of the lifting eye.
CAUTION! Do not start or stop the motor while it is suspended.
If the motor no longer vibrates, possible causes of the vibration are:
− twisted bedplate
− misalignment or eccentricity between the shafts
− improper compression in the coupling pin bushing or an incorrect
division of pins. (This is often the cause if the vibration increases with
load.)
− a defect in the driven machinery
2. If the motor continues to vibrate while suspended:
− remove the coupling.
− Place a full-length key in the keyway and secure it with adhesive tape.
− Repeat the test described above.
− If the motor continues to vibrate, there is an imbalance in the rotor.
If the motor does not vibrate, there is an imbalance in the coupling.

HINTS TO DETERMINE THE CAUSE OF WINDING DAMAGE

− A winding which burned out due to overload is usually uniformly black
and brittle
− Cut-off of one phase causes the other phases to darken in various
stages
− A short circuit due to an insulation defect usually burns only a few coil
sections black. There is also localized burning at the location of the
defect
− If a motor, which has been running well, becomes weak (slip increases
at a certain torque), the defect is often in a cage winding. The brazed
joint in a copper or brass winding has failed, or some bars in an
aluminum winding are broken. A defective brazed joint can usually be
repaired. The rotor must be replaced if a cast aluminum bar is broken
RTG Maintenance Vol 2 – Preventive Maintenance – Motors 76

HOIST MOTOR

MOUNTING POSITION OF MOTOR

Motors are equipped with drain holes. Drain holes are placed on bottom side
(180o degree from terminal box). Motors must be mounted so that terminal box is
on top.
NOTE: Make sure that drain holes are downwards.
RTG Maintenance Vol 2 – Preventive Maintenance – Motors 77

DISASSEMBLY OF THE MOTOR

READ THIS FIRST

WARNING ! Prior removing the motor from the RTG the
safety information at the beginning of this
chapter must be observed.

Typically, it is not necessary to completely disassemble the motor. The following

instructions may be followed to the necessary extent.
When detaching the motor parts with an extractor, protect the edges of the
threaded hole at the shaft end from being damaged.
NOTE: Never disassemble or re-assemble the motor parts by hammering.

Disassembly of N-end
1. Unscrew the fastening screws on the external fan .
2. Release fixing screws of sensor cover (12).
3. Remove speed sensor (11). Loosen two hexacon socket screws M4x6 to
release speed sensor from shaft. Remove holder of speed sensor.
4. Unscrew the fixing screws of the end shield. Unscrew the fixing screws of
the inside bearing cover, if any.
5. Motor M25 remove the grease valve disc by unscrewing it (counter-
clockwise).

6. Pull the end shield off. Do this by using an

extractor in the threaded holes in the shield.
The bearing is to remain in the rotor shaft.
1
NOTE: When removing the end shield, do
not damage the ends of the stator
windings.
7. Pull the ball bearing from the shaft either:
- by using an extractor which grips the
edge of the groove in the inner race of
the bearing, or
2
- by placing a drawing disc between the
bearing and the inner bearing cover.
This will apply pressure to the inner
race only.

Disassembly of D-end
1. Unscrew the fastening screws of the end shield. Unscrew the fastening
screws of the inner bearing cap and remove the outer bearing cap, if
any.
RTG Maintenance Vol 2 – Preventive Maintenance – Motors 78

2. Unscrew the locking screw (1) of the grease

valve disc. Remove the grease valve disc by
1
using an extractor in the threaded holes (2) in
the ring.
3. Remove the end shield and the bearing as
described later.
4. Remove the rotor if necessary.

RE-ASSEMBLY OF THE MOTOR

READ THIS FIRST

WARNING ! Prior installing the motor to the RTG the safety
information at the beginning of this chapter must
be observed.

1. Remove all of the old grease from the bearings. Renew the grease in the
lubrication channel if necessary. Wash the old bearings with white spirit.
Grease them lightly to prevent them from rusting. Do not remove the new
bearings from the packaging until ready for use. Do not remove the anti-
rust grease from the new bearings before use.
2. Replace the rotor if it was removed. Heat the bearings to a temperature
of 80 to 90 oC in an oil bath or in an oven. Push the bearings onto the
shaft.

WARNING ! Use protective gloves when handling hot bearings.

Make sure to keep the gloves clean to prevent
them from collecting dirt.

3. Use the appropriate lubricant as listed in separate section to lubricate the

bearings as follows:
− Completely fill in the space between the inner and outer race of the
bearing with grease
− When bearing has a grease valve, also fill the inside bearing cover
with grease
− Saturate the felt strip with grease
− Lightly grease the sealing surfaces of the inside and outside bearing
cover against the bearing housing and the shaft.
RTG Maintenance Vol 2 – Preventive Maintenance – Motors 79

4. To install the grease valve discs, screw the N-ring clockwise onto the
thread of the shaft. Fix valve discs with locking screw.
5. To lock the axial position of the rotor, fix one of the bearings in the axial
direction. In motor M25, the N-end bearing is fixed. First, install the end
shield of the fixed bearing end. If there is an inside bearing cover, pull the
end shield into place by means of installing screws fitted into the tapped
holes in the inside bearing cover. Screw in the fastening screws for the
end shield. Tighten them in crosswise sequence. Tighten the screws of
the bearing cover.
6. Next, install the opposite end shield. Push it within 2 to 3 mm of its final
position. Tighten the fastening screws of the endshield in crosswise
sequence to draw the shield into its final position. Install the bearing
cover.
7. NOTE! To avoid damaging the bearings, it is essential to rotate the
rotor while installing the endshields.
8. Reassemble speed sensor (10). Fasten two hexacon socket screws
M4x6 to fix speed sensor on shaft. Fix speed sensor to its holder.
9. Install the cover of speed sensor.
10. Install external fan.

GANTRY TRAVEL MOTOR

RTG Maintenance Vol 2 – Preventive Maintenance – Motors 80

MOUNTING POSITION OF MOTOR

Motors are equipped with drain holes. Drain holes are placed on bottom side
(180o degree from terminal box). Motors must be mounted so that terminal box is
on top.
NOTE! Make sure that drain holes are downwards.

DISASSEMBLY OF THE MOTOR

READ THIS FIRST

WARNING ! Prior removing the motor from the RTG the
safety information at the beginning of this
chapter must be observed.

1. Disconnect the brake and motor cables.

2. Remove the motor fixing bolts and extract the motor carefully. Check the
coupling.
3. Remove the brake cover (10) and brake heater (9).
4. Remove the brake (1,2) (see separate instruction).
5. Remove steel plate (11) by releasing fixing screws.
6. Disconnect internal brake and motor cables in terminal box.
7. Loosen the fixing bolts of the flanges (M10x60DIN912-A4).
8. Pull the flanges and the rotor out. (Use plastic hammer if needed).
9. Remove the seals and bearings only if needed.

ASSEMBLY OF THE MOTOR

READ THIS FIRST

WARNING ! Prior installing the motor to the RTG the safety
information at the beginning of this chapter must
be observed.

1. Install new bearings onto the shaft by either warming the bearings
(100 oC/212 oF) or by using a proper “pipe-like” device that fits over shaft
2. Bearings must taped lightly onto the shaft
3. Turn the stator sideways
4. Insert the rotor shaft with its bearing into the stator
5. Place the steel wave spring in the bottom of the bearing housing of driving-
end flange
6. Mount driving-end flange to its place so that the bearing is inserted to
housing. Fasten driving-end flange fixing screws. Do not forget to install
the spring washers (A10DIN127-A4)
RTG Maintenance Vol 2 – Preventive Maintenance – Motors 81

7. Install the nondriving-end flange and remember to install brake and heater
cable through steel plate (11) and nondriving-end flange. Check sealings
of feedthrough
8. Fasten fixing screws of nondriving-end flange. Do not forget to install the
spring washers (A10DIN127-A4)
9. Mount steel plate (11) by fastening fixing screws. Check sealings between
flange and steel plate (11)
10. Install the brake (see separate instruction)
11. Replace the brake cover (10) and the brake heater (9)

ACM AND TROLLEY TRAVERSE MOTOR

MOUNTING POSITION OF MOTOR

Motors are equipped with drain holes. Drain holes are placed on bottom side (
180o degree from terminal box). Motors must be mounted so that terminal box is
on top.
CAUTION! Make sure that drain holes are downwards.
 RTG Maintenance Vol 2 – Preventive Maintenance – Motors 82

DISASSEMBLY OF THE MOTOR

READ THIS FIRST

WARNING ! Prior removing the motor from the RTG the
safety information at the beginning of this
chapter must be observed.

1. Loosen brake cover (13) by unscrewing the fixing screws.

2. Remove speed sensor (12). Loosen two hexacon socket screws M4x6 to
release speed sensor from shaft. Remove holder of speed sensor.
3. Remove brake (1,2). See separate instructions. Note ! steel plate (10) are
mounted with fixing screws of brake. Disconnect the brake wires from the
terminal box if needed.
4. Disconnect internal brake and motor wires from the terminal box.
5. Loosen the long fixing screws (14).
6. Remove the non-driving end flange from the stator frame by tapping the non-
driving end of the shaft.
7. Pull the stator frame out over the rotor.
8. Take off the retaining ring of the bearing housing and remove the bearing from
the driving end flange.
9. Remove the retaining ring and bearing from the shaft with an extractor.
10. Remove any shaft seals and wave springs from bearing flanges.
11. Disconnect the brake wires from the terminal box.

ASSEMBLY OF THE MOTOR

READ THIS FIRST

WARNING ! Prior installing the motor to the RTG the safety
information at the beginning of this chapter must
be observed.

1. Install new bearings onto the shaft by either warming the bearings (100 °C /
212 °F) or by using a proper “pipe-like” device tha t fits over shaft.
2. Bearings must taped lightly onto the shaft.
3. Place the bearing of the non-driving end of the motor on the shaft.
4. Install the retaining ring for the bearing housing of the driving end flange on
the shaft and install the bearing.
5. Place shaft seal in the bearing flange and install the retaining ring of the
driving end bearing.
6. Install all possible seals in the both end flanges.
7. Insert the driving end bearing of the rotor into bearing housing in the end
flange.
RTG Maintenance Vol 2 – Preventive Maintenance – Motors 83

8. Put the stator frame on the rotor.

9. Put the wave spring in the bearing housing of the non-driving end flange and
install the non-driving end flange onto the stator frame.
10. Fasten both flanges with long fixing screws (14).
11. Install the brake (1,2) and check the air gap. See separate instructions.
12. Reassemble speed sensor (12). Fasten two hexacon socket screws M4x6 to
fix speed sensor on shaft. Fix speed sensor to its holder.
13. Fasten brake cover (13) by fixing screws.
14. Connect the leads of the brake magnet to rectifier and fasten the cover of the
terminal box.

PIVOT LOCKING MOTOR

MOUNTING POSITION OF MOTOR

Motors must be mounted vertically
RTG Maintenance Vol 2 – Preventive Maintenance – Motors 84

DISASSEMBLY OF THE MOTOR

READ THIS FIRST

WARNING ! Prior removing the motor from the RTG the
safety information at the beginning of this
chapter must be observed.

1. Open the cover of the terminal box.

2. Loosen mounting screws of the cover to release the cover.
3. Unscrew 4 fixing bolts to release motor from gear.
4. Place motor on table with driving end facing down.
5. Remove end flange from the stator frame by unscrewing 4 fixing screws.
6. Pull end flange upward to release it from fitting in the stator frame. Rotor may
follow, if bearing fits tight.
7. Slide out rotor.

ASSEMBLY OF THE MOTOR

READ THIS FIRST

WARNING ! Prior installing the motor to the RTG the safety
information at the beginning of this chapter must
be observed.

1. Install new bearings onto the shaft by either warming the bearings (100 °C /
212 °F) or by using a proper “pipe-like” device tha t fits over shaft.
2. Bearings must taped lightly onto the shaft.
3. Place the stator frame so that driving end of the motor is facing down.
4. Slide wave spring and rotor together into stator frame .
5. Compress end flange (4) on to the bearing and fitting in stator frame.
6. Place steel plate (5) on the end flange (4) and fasten it to frame with 4
hexagon screws.
7. Insert motor fitting in gear and tighten the 4 fixing bolts.
8. Place cover (6) against stator frame and tighten screws.
RTG Maintenance Vol 2 – Preventive Maintenance – Motors 85

REPLACING THE MOTOR

RECEIPT AND STORAGE OF A SPARE MOTOR

Inspect the motor immediately upon receipt. Verify that there is no damage due to
transport. Verify that the rating plate values correspond to the order. Verify that
the power supply is compatible with the values specified on the rating plate. If the
motor is to be stored prior to installation, it must be kept indoors at room
temperature in order to keep the insulation dry. If the motor is stored for more
than six months, manual rotation of the shaft is recommended every two months.
The rotation will distribute the oil in the bearing grease.
WARNING! When lifting the motor, use the lifting eye bolt on the stator
frame or two lifting slings placed under the stator frame.

Check the following before installing

1. Free rotation of the rotor. Verify that all temporary transport supports for the
bearings, if any, have been removed.
2. Insulation resistance. Check the insulation resistance in accordance with the
instruction described in this paragraph (under ‘Inspection and Maintenance’).
Check the insulation a few days before use since the winding may need
drying.
3. Ambient temperature must not exceed 40 oC (104 F), unless otherwise stated
in the order. The flow of the cooling air must not be obstructed. Expelled air
must be freely discharged and it must not be directed back immediately.

DRIVEN MACHINERY
Use solvent to clean the shaft ends and the contact faces of the flanges. Note that
the shaft ends and the contact faces of the flanges are treated against corrosion.
NOTE! The solvent must not penetrate the bearings.
To prevent damaging the bearings, do not hammer or strike the shaft of
the motor.

LOCATION
Motor shall be mounted so that the drain holes are at the bottom.

PHASE WINDINGS
The insulation class of the stator windings is stated in the rating plate. The
insulation class is typically class F.

CONNECTION TO MAIN SUPPLY

The terminal board strips are in the position corresponding to the type of
connection stamped on the motor rating plate.
RTG Maintenance Vol 2 – Preventive Maintenance – Motors 86

W2 U2 V2 W2 U2 V2 W2 U2 V2

U1 V1 W1 U1 V1 W1 U1 V1 W1

L1 L2 L3 L1 L2 L3 L1 L2 L3

Y-Connection D-Connection Y-D-Starting

(Strips
removed)

NEW MOTOR START-UP

Before Operating the Motor

Check the following:
1. Direction of rotation of the motor. The direction of rotation may be
reversed by interchanging any two main supply wires which connect
to the pole screws (U1, V1, W1) of the motor. Verify that the direction
of rotation of the motor corresponds to the direction of the control
commands. Symmetrically installed bridge travelling machine units
operating on different rails have opposite directions of rotation.
2. Operating noise. A loud growling sound from the motor indicates that
the connection is faulty, and the motor must be stopped immediately.
During operation, the bearing should make a humming sound. If
there is a distinct rattling sound from the bearing, the bearing is
damaged and must be replaced immediately.
3. Vibration. The cause of any exceptional vibration in the motor must
be determined.
4. Load condition (recommendation). Measure the stator current from
each phase. Measure the speed of rotation with a tachometer or by
slip-measurement. Compare the values obtained with the values
specified on the rating plate. Verify the actual starting frequency does
not exceed the values stated on the order.
5. Running temperature. Check the temperature after the first long-term
use. The motor will reach it's final running temperature in
approximately three to five hours after starting. To check the
temperature, first feel the stator frame. If the temperature of the
stator frame feels as though it has exceeded 50 oC (122 F) , use a
thermometer to obtain an accurate temperature reading. Place the
bulb of the thermometer in the bolt hole of the lifting eye or on the
surface of the stator frame inside the terminal box. The temperature
rise of the winding must not exceed 100 oC (212 F) in motors with F-
class insulation.
 RTG Maintenance Vol 2 – Preventive Maintenance – Gear Boxes 87

GEAR BOXES
READ THIS FIRST
WARNING ! - Read the general safety precautions at the
beginning of this manual.
- Special safety information is provided at the
beginning of a chapter or specific point in the text.
- To avoid accidents, the safety from moving or
rotating machinery must be ensured.
- Do not wear garments with loose sleeves or
accessory which might get entangled with the
mechanical parts.
- Lock off the supplies to all crane drives before
maintenance work is started.
- Before inspecting or servicing the gear make sure
that the shaft is prevented from rotating by locking it
and isolating the electrical power to the
corresponding motors.
- During the maintenance work, do NOT remove the
gear while there is any external torque applied to
the shaft.
Unusual In the event of unusual changes to the gear, power supply must be
changes immediately be disconnected. Any unusual changes, e,g. unnormal
with gears vibration or noise must immediately be reported to the person
concerned or the customer service department notified in order to
prevent the mtor suffering further damage.

CONSTRUCTION OF KONECRANES GEAR UNIT

KONECRANES helical gear units consist of standardized construction parts. Center
distance and nominal transmission ratios are according to Renard series R20.
The frame of the gear unit is rigid to withstand deformation caused by both internal
and external loadings of the gear unit. The external surfaces of the gear units are
smooth and easy to clean. The housing is coated with oil resistant epoxy paint.
The gear case is manufactured from structural steel Fe52 (S355) or cast iron GG20.
The pinions and the gear wheels are made of case hardened steel. Based on the
dimensions of the raw material, the following steels are used:
− 21NiCrMo2 (AISI 8620)
− 20NiCrMo5
− 17CrNiMo6
All gears are case hardened and ground to accuracy grade 6 DIN 3961.
Bearings are taper roller bearings or cylindrical roller bearings.
 RTG Maintenance Vol 2 – Preventive Maintenance – Gear Boxes 88

On the secondary shaft, a radial shaft seal made of nitrile rubber type AS DIN 3760
with a lip seal against dust is used. The primary shaft seal is made of viton.
The gears are normally splash lubricated. There is no need for a lubrication pump
when 3- and 4-stage gears are used in vertical position. The oil level is possible to
check through the oil eye. Gears have been equipped with a vent cap, magnetic plug
and lifting eyes. The gears have plugged thread holes to be used when draining the
oil.

INSPECTION AND MAINTENANCE

Gear maintenance is generally limited to control of the oil quantity, quality, changing
the oil and greasing all grease points. In connection with these measures, verify that
the gear mounting and installation have not changed. While running the gear,
following points shall be observed:
− overheating
− operating noise
− vibration
− oil circulation
− gear sealing
− operating capacity
− The breathing plug is free of dust
The highest permissible operating temperature for the gear reducer is 80 ºC (176 F).
Measure the operating temperature from the oil reservoir in the gear unit. In special
cases, (i.e. high ambient temperature), a higher operating temperature may be
permitted.
The selected lubricant must be appropriate for the ambient temperature.
Variations in operating noise and vibration may be signs of damage. To minimize
damage, the cause of the variations must be immediately determined.
Condition of the gear wheel shall be checked once a year (i.e. during the oil change).
If there is any change in tooth contact, wear or defects, those must be immediately
repaired. The bearings must also be checked at this time.
Lubrication and related procedures must be performed correctly to ensure trouble-
free performance and a long, operational lifetime of the gear unit. For normal service
conditions the list of recommended lubricants may be used as a general guide. Refer
to ‘Lubrication – Gears’ section in this manual.

STORAGE OF THE SPARE GEAR REDUCER

The gear reducer must be stored in a warm, dry location.
Check the corrosion inhibition on the inner surfaces once a year. Renew the
corrosion inhibition if necessary. Make sure to check the bearings.
It is recommended that gear reducers which will be stored for a long period of time in
a corrosive environment are completely filled with oil. If this is not possible, the inside
of the gear reducer must be sprayed with a corrosion inhibitor in short intervals.
Between intervals, the inside of the gearbox must be dried i.e. with a heater.
Inside of the gearbox must be inspected to ensure that extensive corrosion does not
occur. Improper storage may cause serious damage in a short period of time.
 RTG Maintenance Vol 2 – Preventive Maintenance – Gear Boxes 89

PROCEDURE FOR INITIAL USE OF THE GEAR UNIT

All gear wheels of KONECRANES gear reducers are hardened and ground; therefore
the gear may be fully loaded at the initial startup.
If the gear unit has been in storage for a long period, all bearings must be lubricated.
The bearings shall be manually lubricated through the inspection hole before startup.
To ensure that all bearings have a lubricant film in a startup shall the shafts be
rotated by hand during the lubrication. Prior to start-up, check the installation of the
gearbox and fill the gear with oil.
The gearbox must be properly fastened to prevent unexpected movement of the
gearbox. There are noticeable forces in the machinery when it is under loadings
during start-up. It must be verified that the forces due to power transmission do not
exceed the designed strength of the gear reducer and its components. The gear
reducer is designed to carry only torque applied to its input and output shafts. If there
will be any other exterior forces i.e. radial forces on shafts - KONECRANES must be
consulted.

INSTALLING GEAR BOX

READ THIS FIRST

WARNING ! Prior installing the gear to the RTG the safety
information at the beginning of this chapter must be
observed.

Carefully done installation will help to ensure the proper operation of the gearbox.
Improper installation may cause serious damage to the gearbox and other structures.
The use of a damaged gearbox may cause damage to other equipment and lead to
unnecessary danger.
To prevent any vibrations must the gear be mounted straight. Gear must be
carefully supported before the fastening bolts are tightened. These precautions
will prevent deformation and unexpected stresses, which could change the
tooth contact and damage the teeth.

GEARBOX OPERATION
KONECRANES gearboxes are manufactured to efficiently reduce rotational speed in
power transmission applications.
Overloading causes serious damage in a short period of time and may result in a
total breakdown.
If allowable loading conditions are not clear, please contact Konecranes to obtain the
correct information. Provide the serial number and type of gear unit printed on the
gear unit to facilitate the identification of the gearbox.
 RTG Maintenance Vol 2 – Preventive Maintenance – Couplings 91

COUPLINGS
READ THIS FIRST
WARNING ! - Read the general safety precautions at the
beginning of this manual.
- Special safety information is provided at the
beginning of a chapter or specific point in the text.
- To avoid accidents, the safety from moving or
rotating machinery must be ensured.
- Do not wear garments with loose sleeves or
accessory which might get entangled with the
mechanical parts.
- Lock off the supplies to all crane drives before
maintenance work is started.
- Before inspecting or servicing the gear make sure
that the shaft is prevented from rotating by locking it
and isolating the electrical power to the
corresponding motors.
- During the maintenance work, do NOT remove the
coupling while there is any external torque applied
to the shaft.
Unusual In the event of unusual changes to the coupling, power supply must
changes be immediately be disconnected. Any unusual changes, e,g.
with unnormal vibration or noise must immediately be reported to the
couplings person concerned or the customer service department notified in
order to prevent the mtor suffering further damage.

GANTRY MOTOR COUPLING

MOUNTING

READ THIS FIRST

WARNING ! Prior installing the coupling to the RTG the safety
information at the beginning of this chapter must be
observed.
 RTG Maintenance Vol 2 – Preventive Maintenance – Couplings 92

1. Coupling
4 3 1 2 5
Motor Gear
2. Turned groove
shaft shaft 3. Retaining ring
4. O-ring
5. O-ring

1. The paint, burrs etc. is removed from the contact surfaces of the motor and the
gear.
2. Lubricate the o-ring and assemble it on the gear primary shaft

Gear
shaft

3. Assemble the retaining ring in the coupling and lubricate the toothing and the
sliding surfaces of the o-rings, fig. 3.
4. Lubricate the toothing of the motor and the o-ring on the shaft.

Retaining ring

5. Ensure that the o-rings on the motor and the gear shaft and the retaining ring in
the coupling is correctly assembled and on their places.
6. Try with the unfastened coupling that it fits on the toothed shaft of the motor/gear.
 RTG Maintenance Vol 2 – Preventive Maintenance – Couplings 93

Note! The turned groove on the coupling surface must always be on

the gear side.
7. Push the coupling on the toothing of the motor shaft until the o-ring stops the
movement, (ca. 10 mm). If the coupling slides easily, it can be pushed until the
o-ring stops against the toothing.

Motor
shaft

8. The motor is lifted with e.g. a hoist block thus it is horizontally in balance.
Hint: Release the brake manually.
9. The motor with coupling is fitted on the gear shaft. The motor is by hand
pushed on the toothed shaft of the gear until the o-ring stops the movement,
(ca. 10 mm ~25/64 inches). If the coupling slides easily, the motor can be
pushed against the contact surface of the gear.
10. If you can feel a clearance between gear and motor and the motor will not fit
on the gear shaft, pushing by hand, the motor must be detached from the
gear shaft, and the gear shaft must be rotated a bit. Follow instruction 9.
11. When the motor with coupling is fitted on the gear shaft toothing, you
cannot feel any radial clearance between motor and gear, regarding to the
motor and gear shafts.

M oto G ear
rrr
shaf shaf
t t
 RTG Maintenance Vol 2 – Preventive Maintenance – Couplings 94

12. Assemble the motor fixing bolts and tighten them crosswise, thus a
possible gap between the motor and gear contact surfaces decreases
evenly by every fixing bolt.
Note! Lock bolts with locking liquid.
13. Inspect visually or with a feeler gauge that there will not remain a gap
between the contact surfaces.

INSPECTION OF THE COUPLING

1. Turn bogie to cross position.
2. Remove the motor (check the ‘Gantry Motor’ paragraph in ‘Motors’ section).
3. Remove coupling by pulling it out from the shaft by hands.
4. Check the teeth for wear.
5. Fit a new coupling, if a shoulder has worn in the teeth. If the rubber rings (4) or (5)
have deteriorated or are worn, they should be changed.
6. Check the retaining ring for wear and replace it with a new one if it is worn.
7. Degrease the coupling and then lubricate it and the rubber rings with grease
RENOLIT FLM2 or corresponding.
8. Always fit the coupling in the original position. The turned groove (2) on the
coupling surface must be on the gearbox side.
9. Install the motor. (Check the ‘Replacing the Motor’ paragraph’ in ‘Motors’ section)

LOCKING DEVICE COUPLING

Motor coupling (1G1108) consist of
five parts: coupling, two securing
piece and two o-rings. Securing
pieces are situating at the center of
coupling, inside the spline, and are
either simple retaining rings or
shaped plate rings. O-rings fit to shaft
groove and they have three
functions:

- they keep coupling centered

- they prevent the axial movement
- they keep grease inside the
coupling

If o-ring fails to keep the coupling in

its place the securing piece will finally
prevent the axial movement

Gear coupling assembly

 RTG Maintenance Vol 2 – Preventive Maintenance – Couplings 95

MOUNTING

READ THIS FIRST

WARNING ! Prior installing the coupling to the RTG the safety
information at the beginning of this chapter must be
observed.

1. Remove the motor (Check the ‘Pivot Locking Motor’ in ‘Motors’ section).
2. Remove the coupling.
3. Check that all parts and contacting surfaces are clean and in a perfect
condition.
4. Check by measuring that groove distance ( e ) will be correct after assembly
and width of splines ( bG, bM ) are correct.

Type e [mm] bG [mm] bM [mm]

1G1108 19.8 +0.2 6.0 - 7.5 4.5 - 5.5
5. To check the groove distance measure the distance from motor face surface to
the shaft groove of the motor. Then measure the distance from gear face
surface to the shaft groove of the gear. The sum of these two values must
correlate the table value of e.
6. Checking of distances is not possible after coupling is assembled.
7. Check that coupling fits on splines by testing it separately both on motor shaft
and on gear shaft. Tiny groove outside the coupling should face outwards from
the motor.
8. Fit O-rings gently to shaft grooves (both gear and motor side). Use thin layer of
gear coupling lubricant (see clause 4.) on rings which helps the assembly.
Beware to not break o-rings during assembly.
9. Ensure that o-rings are on shafts and the securing ring inside the coupling is
correctly assembled to its place.
10. Spread good amount of gear coupling lubricant on spline teeth. Notify the tiny
groove outside the coupling which must face outwards from the motor. Push the
coupling on motor shaft until it stops against o-ring. Coupling should slide
easily. Do not use force.
11. Fill the securing ring pocket with coupling lubricant and spread lubricant also on
gear spline if not done already.
12. Before attaching the motor to the gear make sure the motor shaft can be
rotated freely (e.g. disengage the motor brake).
13. Lift the motor with a sling around it or from the lifting eye up to the same level
than the gear shaft. (Check the ‘Replacing the Motor’ paragraph in ‘Motors’
section).Move the motor horizontally and gently by hands towards the gear and
fit the coupling end on the gear spline. Rotate motor slightly by hands to get the
splines to the same position.
 RTG Maintenance Vol 2 – Preventive Maintenance – Couplings 96

15. Make sure that shafts are parallel and at the same level. Push the motor gently
to fit the coupling on spline. Do not use force. The clearance between facing
surfaces should close easily. If it does not, check that shafts are coaxial and in
line.
16. If there is a clearance between joint surfaces or if motor does not set properly,
pull the motor off gently, check parts, rotate motor shaft about quarter turn and
proceed from point 10.
17. Set motor fixing bolts and tighten them crosswise and evenly first by hands and
then with tools. Tighten bolts up to final torque.

BOLT SIZE (8.8) TORQUE Tt [Nm] ft – lbf

M6 8 5.9
M8 20 14.7
M10 38 28
18. Check and ensure that there will not be clearance between joint surfaces after
assembly.

INSPECTION OF THE COUPLING

- NOTE ! Always make sure that the coupling is not loaded before opening the
joint.
- In addition to the routine inspection intervals the coupling must be inspected
always if abnormal vibration or sound is detected from machinery.
- Check that the coupling is lubricated properly.
- If the coupling is damaged and deformation can be seen or if there are any
surface cracks on teeth the coupling must be replaced with a new one. This also
indicates possible overloading of machinery, which must be checked.
- If fretting or pitting is found the coupling is still usable, but it must be inspected
carefully after 1 month or 250 operating hours. If progressive wear cannot be
determined after this the inspection interval may be prolonged to be done every 3
months or 750 hours. If wear is increased the coupling must be replaced with a
new one.
- In the case of damage, pitting or fretting the alignment of the shafts must be
checked and possible misalignment should be corrected. Refer to diagram for
feasible region of misalignment.
- If o-rings are worn they must be replaced with new ones.
- Check always that the securing piece is correctly on its place.
- Add lubricant always after inspection.
 RTG Maintenance Vol 2 – Preventive Maintenance – Couplings 97

HOIST MOTOR COUPLING (GO1-AMM)

DESCRIPTION
1. Hub
2. Flanged sleeve
3. Sized screw
4. Hexaconal nut
5. Grease nipple
6. Thoroidal hub
7. Longer hub

REPLACEMENT OF HOIST MOTOR COUPLING

READ THIS FIRST

WARNING ! Prior installing the coupling to the RTG the safety
information at the beginning of this chapter must be
observed.
Work only with the driving machine off or in
emergency and the driven machine shafts locked.
1. Remove the packing of the coupling. When the Maina couplings are supplied
with a protection allowing their stockage in an open-air place and in industrial or
sea environments, remove this protection before the fitting and clean the
surfaces to be connected thoroughly (hub holes and shafts). When using toxic
subtances take the necessary precautions.
2. Position the flanged sleeves on the shafts.
3. For an easier fitting of the hubs, which we recommend to carry out with a slight
interference fit (H7-r6 or equivalent), heat the parts thoroughly in an oil dip
(120°… 130°C or 248...266 F) or with a flame, witho ut exceeding
130°C (266 F). When using the flame heat the hubs f rom the outside.
4. Carry out these operations with the maximum safety conditions.
5. Remove the carbon residues formed during the heating.
6. Shrink the hubs on making sure that the flanged sleeves are positioned on the
shafts with the thoroidal gaskets in the proper seats. Avoid contacts between
the gaskets and the hubs until the temperature of the hubs has fallen below
100°C (212 F).
7. Position the machines so that the distance between the hubs or the shafts is
equal to the one indicated in the catalogue or on the drawing.
NOTE! The spare couplings are supplied without lubricant, therefore once the hubs
are fitted, using a spatula, fill the space between hub and flanged sleeve
with a grease with the characteristics indicated in the Lubricant Group 11.
 RTG Maintenance Vol 2 – Preventive Maintenance – Couplings 98

8. For a good seal smear the flanges with the special putty and couple them
positioning the four grease nipples at 90°.
9. Mount all the screws ensuring that the tightening torques are 50 Nm (36 lb-ft)
10. Complete the grease filling using the grease nipples.
11. Follow the inspection procedure (next paragraph)

INSPECTION OF A COUPLING
1. Remove hatches (2 pcs) of hoist coupling tube. Gear teeth can be seen through
the hatches.
2. Check that no single gear tooth is damaged. Otherwise change the coupling.
3. Check that the flanged sleeves can freely move axcially of ± 1.5 mm
(± 1/16 inch).
 RTG Maintenance Vol 2 – Preventive Maintenance – Couplings 99

HOIST DRUM COUPLING

DESCRIPTION
Main parts of Drum Coupling
(GC07200) are tooth ring (1),
torque ring (2), D18 spring
pins (10), M10 fixing bolts (8) and
hardened washers (9). These are
load carrying parts. For
lubrication of coupling there are
back cover (3), sealing cover (4),
O-ring (5), lubricating nipple (6)
and air discharge screw (11).
Screws (7) and (12) are used for
fixing of covers
Shaft torque is transmitted
through the internal spline to
tooth ring (1). Through the
external spline torque is
transmitted to torque ring (2)
which is coupled to drum flange
with bolts (8), washers (9) and
spring pins (10). Tooth ring
allows minor misalignments
between coupled shaft and drum.
 RTG Maintenance Vol 2 – Preventive Maintenance – Couplings 100

REPLACEMENT OF HOIST DRUM COUPLING

READ THIS FIRST

WARNING ! Prior installing the coupling to the RTG the safety
information at the beginning of this chapter must be
observed.
Work only with the driving machine off or in
emergency and the driven machine shafts locked.
1. Remove the old coupling.
2. Check that all parts and contacing surfaces are clean and in a perfect condition.
3. Check by measuring that assembly dimensions of shaft and drum can be
fulfilled.
4. Check that tooth ring fits on splines by testing it separately both on shaft and
into torque ring.
5. Check length of spring pins before assembling them. Ensure by measuring that
spring pins will have room in spring pin holes.
6. Set two guiding spring pins to drum flange by hammering them gently.
7. Ensure that back cover is assembled to torque ring before setting the ring into
its place on drum flange.
8. If needed rotate torque ring slightly to align spring pin holes and set auxiliary,
long fixing bolts. Tighten bolts crosswise and evenly with tools. Clearance
between facing surfaces should close evenly.
9. If clearance is closed properly set fixing bolts and washers to holes which has
spring pins in it. Tighten M10 bolts (8.8) to final torque 40 Nm. Remove other
bolts.
10. Assemble remaining spring pins into their holes by hammering them gently.
11. Set remaining fixing bolts and washers and tighten them crosswise and evenly
to final torque.
12. Spread coupling lubricant on both torque ring spline and tooth ring external
spline and set the tooth ring inside the torque ring.
13. Assemble the sealing cover (4) with the O-ring to the coupling.
14. Set the gear shaft to the same level than the drum and spread lubricant also on
gear shaft spline and tooth ring internal spline.
15. Set the coupling on the gear shaft and move the gear horizontally and gently
towards the drum and fit the coupling end on the gear spline. Rotate gear shaft
slightly to get the splines to the same position if needed.
16. Make sure that shaft and drum are parallel and at the same level. Push the
Gear shaft into drum gently to fit the coupling on spline until the gear shaft end
hits the back cover (3).
17. Fit the gear and the drum together on their place on the end carriages, lock the
gear end of the drum preliminary with the bearing housing cover. Pull the drum
away from the gear about 4.5 mm (11/64 inch), when the toothing of the shaft is
in its correct position. Fix preliminary the free end of the drum.
 RTG Maintenance Vol 2 – Preventive Maintenance – Couplings 101

18. Measure the angular misalignment as described in the following paragraph.

If mis-alignment D is under 0.8 mm the gear and drum may be fixed properly.
19. If the angular misalignment is more than 0.8 mm corrective actions should be
taken.
20. Remove the air discharge screw and fill the coupling with a proper drum
coupling lubricant. Put the air discharge screw back after coupling is filled up
with grease.

MEASURING THE MISALIGNMENT

Maximum misalignment between the gear reducer and hoist drum:

Dimension D to be measured with the micrometer from the machined surface at the
distance of L = 160 mm (6¼”) from the centerline of the drum.

D D D D

L L

Maximum value D = 0.8 mm (1/32 “)

INSPECTION OF THE COUPLING

NOTE ! Always make sure that the coupling is not loaded before opening the joint.
1. If the coupling is damaged and deformation can be seen or if there are any
surface cracks on teeth the coupling must be replaced with a new one. This
also indicates possible overloading of machinery, which must be checked.
2. Alignment of the coupling must be done always after inspection.
Maximum allowed angular misalignment D is 0.8 mm (1/32 “).
Check the previous paragraph for correct measurement.
3. Replace the lubricant completely after inspection.
 RTG Maintenance Vol 2 – Preventive Maintenance – Gantry Bogie 103

GANTRY BOGIE
GENERAL
Each gantry bogie consists of two rubber tyred wheels on a single axle. The gantry
travel machinery is between the wheels, but only drives one of the wheels. The other
wheel has bearings in its hub and can rotate freely on the axle.
The gearbox casing is a structural component which is connected to the bogie
balancing beam by two bearings and a vertical kingpin shaft. The upper bearing
supports the main vertical load of the crane onto the bogie. Both bearings support the
horizontal loads that may occur. A carrier plate ring beneath the lower bearing
prevents the kingpin from coming out of the balancing beam structure when the
gantry is jacked up.
A thruster-driven locking pin is mounted on the structure of the balancing beam and
engages into a locking ring on the bogie. This prevents the pivoting motion of the
bogie when it is engaged.
All functions and motions of the bogie are electro-mechanical.
 RTG Maintenance Vol 2 – Preventive Maintenance – Gantry Bogie 104

Each bogie is able to pivot around its vertical axis, so that it can be aligned for Gantry
Long Travel, Gantry Cross Travel and Gantry Turning modes of the crane.
This is done by releasing the pivot locking pin and then running the gantry travel
machinery for a short time. Because only one wheel is driven, the bogie pivots on its
kingpin.
When the bogie is turned to the appropriate preset position, the pivot locking pin is
re-engaged, before any gantry travel motion is allowed. The pivoting sequence for all
eight bogies is automatically controlled from a single "Gantry Travel Mode" selector
switch in the operator's cab.
 RTG Maintenance Vol 2 – Preventive Maintenance – Gantry Bogie 105

REPLACING GANTRY TRAVEL MACHINERY

READ THIS FIRST

WARNING ! - Read the general safety precautions at the
beginning of this manual.
- To avoid accidents, the safety from moving or
rotating machinery must be ensured.
- Lock off the supplies to all crane drives before
maintenance work is started.

JACKING UP THE BOGIE

For jacking instructions please refer to ‘Special Procedures’ – Bogie Jackings-
Jacking the Whole Bogie. (Note: There are two different procedures for jacking the
bogie, the other one is for single wheel change only).

INSTALLING KINGPIN, LOCKING PARTS AND BEARINGS

1. Check that all contacting surfaces are clean, free of paint and in a perfect
condition. Use locking liquid on all bolt threads.
2. Assemble the kingpin onto the gearbox of the gantry travel machinery. Spread
locking liquid onto the bolt threads and insert the twelve fixing bolts (M20x80).
3. Tighten the bolts diagonally crosswise to 80% of the full tightening torque.
When this partial tightening is completed, tighten the bolts diagonally crosswise
to the full tightening torque.
4. Spread a thin layer of locking liquid onto outer surface of a steering lock
bushing and press the bushing into one of the holes in the lock ring.
Repeat the sequence until all bushings are assembled.
5. Insert the locating pin (for the lock ring) into the hole in the top surface of the
gantry travel gearbox. Select the correct lock ring and fit it onto its locating pin.
Check the direction of the pivot lock holes from the assembly drawing. Also,
ensure that the lock ring has the correct angle for the locking hole at the gantry
turning position. This angle is greater for the outer bogies.
6. Spread locking liquid on the threads and assemble the eight fixing bolts
(M20x50) for the lock ring. Tighten the bolts diagonally crosswise to 80% of the
full tightening torque. When this partial tightening is completed, tighten the bolts
diagonally crosswise to the full tightening torque.
7. Rest the protective cover plate on the top of the lock ring and push the V-seal
onto the kingpin. Spread a thin layer of lubricating grease on the sealing surface
and put the carrier plate ring onto the top of the seal.
8. Lightly oil all seating surfaces for the bearings on the kingpin. Ensure that the
V-seal, protective cover and carrier plate are all positioned on the kingpin, then
assemble the lower bearing onto the kingpin.
9. Assemble the spacing ring and the collar onto the kingpin (above the lower
bearing). Then, assemble the inner race of the taper roller bearing onto the
kingpin. Use the fixing parts (plate ring, washer and bolt) to help this assembly.
 RTG Maintenance Vol 2 – Preventive Maintenance – Gantry Bogie 106

10. Assemble the rollers and outer race onto the bearing and tighten the fixing bolt
(M20) to the full tightening torque.
The bogie is now ready to connect to the structure of the balancing beam.

BOGIE INTO BALANCING BEAM

1. Check that the bearing seats inside the balancing beam structure are clean,
free of paint and in a perfect condition. Also, check the perpendicularity of the
seat for the outer ring of the taper roller bearing.
Max. Allowed Perpendicularity Error 0.022 mm (0.000866 inch).
2. Ensure that the balancing beam structure is properly supported and the bogie
can be positioned beneath it.
3. Lightly oil the seating surfaces for the bearings inside the vertical tube of the
balancing beam and then insert the kingpin and bearings assembly.
4. By using a hoist or hydraulic jack, carefully raise the bogie and kingpin
assembly up inside the balancing beam structure until it stops against the seat
of the taper roller bearing.
5. Spread locking liquid on the threads and assemble the four fixing bolts
(M12x90) into the carrier plate. Tighten these bolts diagonally crosswise to 80%
of the full tightening torque. Then, tighten them to the full tightening torque.
6. Before removing the jack or hoist, support the first bogie until the second bogie
is also connected to the other end of the balancing beam.

INSTALLING THE PIVOT LOCKING MACHINERY

1. Check that the locking bar of the thruster is at its shortest "Released" position.
2. Insert the lock machinery into its mounting flange on balancing beam. Check
that it is the correct way round, so that the cover of the limit switch box can be
opened.
3. Assemble the four fixing bolts (M12x50) into the mounting flange.
Tighten these bolts diagonally crosswise to 80% of the full tightening torque.
Then, tighten them to the full tightening torque.
TIGHTENING TORQUES OF BOLTS
Bolt Size (8.8) 80% Tightening Torque Full Tightening Torque
M20 312 N-m (230 lb-ft) 390 N-m (288 lb-ft)
M12 58 N-m (43 lb-ft) 72 N-m (51 lb-ft)
 RTG Maintenance Vol 2 – Preventive Maintenance – Gantry Bogie 107

INSPECTION AND MAINTENANCE

READ THIS FIRST

WARNING ! - Read the general safety precautions at the
beginning of this manual.
- To avoid accidents, the safety from moving or
rotating machinery must be ensured.
- Lock off the supplies to all crane drives before the
inspection or maintenance work is started.
1. Regularly check the wear rate of the bushings in the lock ring where the pivot
locking pin engages.
2. Replace any damaged bushing. When replacing the bushing:
- First turn the bogie so that the thruster is engaged into that damaged
bushing.
- Detach the pivot lock machinery. The bushing can then be replaced via
the hole in the thruster mounting flange.
- Finally, replace the pivot lock machinery.
 RTG Maintenance Vol 2 – Preventive Maintenance – Misc Components 109

INSPECTION OF MISC
COMPONENTS
FIRE EXTINQUISHERS
The type of the fire extinquisher depends on the local regulations.
All of the extinguishers should be inspected on a regular basis, to confirm that they
remain in good condition, and to check that their contents remain full.

Quantity Location Preferred Size

Kg lbs.
1 Operator's Cab 3 6
1 Electrical Equipment Room 6 12
1 Diesel- Alternator Enclosure 6 12
1 Trolley (Optional Location) 6 12
1 Auxiliary Diesel (Optional) 3/6 6 / 12
1 Checker’s cab (Optional) 6 12

ROUTINE INSPECTION OF EACH EXTINGUISHER

Although an monthly routine inspection is suggested, the frequency may be varied to
conform with any local fire safety regulations.
1. Check that there are no signs of external mechanical damage or
corrosion, including the discharge nozzle and pipe.
2. Check that the extinguisher is full, by comparing its weight with that
stated on the manufacturer's label, for a fully charged unit. (or by
checking the charge gauge / meter).
3. Check that the firing safety pin is in place.
4. Check the inspection label / stricker.

RE-FILLING OF A DISCHARGED EXTINGUISHER

Any extinguisher that has been discharged, should be re-filled in accordance with the
manufacturer's instructions, as soon as possible.

STATUTORY INTERNAL INSPECTION & RE-FILLING

Some local fire safety regulations require a statutory internal inspection and re-filling
of all extinguishers at certain regular intervals.
Where applicable, this should be carried out in accordance with these regulations.
 RTG Maintenance Vol 2 – Preventive Maintenance – Misc Components 110

CONTROL EQUIPMENT VENTILATION

Several items of control equipment are fitted with ventilation fans. These ensure that
the heat is removed from components which a have high power dissipation.

EVERY 3 MONTHS OR 750 OPERATING HOURS

The control equipment must be checked to ensure that all of the fans are running
correctly and that the air flow is not obstructed.
Check filters where applicable.
If these fans are not working correctly, the equipment will overheat. This is likely to
lead to an equipment failure and hence the break- down of the crane.

Motor Control Equipment (Inverters) Location

Hoist Inverters (x2) Electrical Equipment Room
Gantry Travel Inverters (x8) Electrical Equipment Room
Trolley Traverse Inverter (x1) Electrical Equipment Room
ACM Inverter (x4) Trolley Cubicle

EVERY YEAR OR 3000 OPERATING HOURS

It is likely that there will be a build up of accumulated dirt on the control equipment,
despite the best efforts to maintain a high level of cleanliness in the rooms and
cubicles.
Each year, any loose dirt must be removed from all control equipment.

Cleaning Locations
Operator's Cab Equipment Cubicle
Trolley Equipment Cubicles
Electrical Equipment Room
For each location, the procedure is as follows:
1. During this work, isolate the electrical supplies to all components, including to
the panel heaters. (The temporary site supply must also be switched off).
2. Using a vacuum cleaner with an insulated (plastic) nozzle, remove any
accumulated dirt from the control equipment and from the cubicles / rooms.
3. When this cleaning work is completed, re- energize the electrical supply to the
anti- condensation heaters for the equipment and panels.
 RTG Maintenance Vol 2 – Preventive Maintenance – Misc Components 111

INSPECTION OF THE RESISTOR BANKS

Locations of the resistor banks are on the top of the Electrical room and next to the
ACM Inverter cubicle on the top of the trolley. This procedure applies to both of these
resistor banks.
1. Open resistor bank covers loosening four (4) screws.
2. Check that the resistor bank’s cables are properly tightened to bottom
of the cubicles by means of cable ties.
3. Clean resistor banks out of dust using the water or airpressure.
NOTE! If water is used for cleaning let the resistor banks to dry at
least 24h before operating the crane.
4. After cleaning measure the insulation resistance from the Electrical
room contactors A-K51 to A-K54. Make sure that contactors are not
energized while measuring. Measure also trolley inverter resistor
banks from inverter itself. Remove resistor banks plus (+) and minus
(-) leads before measuring. Write values down and use them as
reference values for next time or during fault finding.
5. Close the covers of the resistor banks.
 RTG Maintenance Vol 2 – Preventive Maintenance – Cab Window Cleaning 113

CAB WINDOW CLEANING

READ THIS FIRST
WARNING ! Make sure that the RTG is prevented from moving
prior starting the cleaning work.

Main Front Window Main Front Window

Upper Front Window Left Side Front Window

Left Side Rear Window Left Side Rear Window

 RTG Maintenance Vol 2 – Preventive Maintenance – Cab Window Cleaning 114

Right Side Rear Window Right Side Side Window

Right Side Side Window Right Side Front Window

Right Side Front Window Cab Floor Window

 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 115

SPECIAL PROCEDURES

A. STRUCTURAL INSPECTION
This section includes instructions of visual inspections of all welds, bolted joints and
surface coatings of the RTG Crane.

READ THIS FIRST

WARNING ! Prior starting the structural inspection the safety
information at the beginning of this manual must be
observed.

INSPECTION METHODS
In general, non-destructive testing (NDT) is sensitive to the external conditions and to
the characteristics of the structure. Inspections must be carried out by qualified
professionals using recognized methods.
If there is any suspicion of a crack, the weld must be examined thoroughly, so that
the extent of the defect can be fully assessed.

VISUAL TEST (VT)

Dirt and grease should be removed from surface by wiping with a rag. The surface
should be inspected for cracked paint and rust showing through the paint. A good
light (torch) and a magnifying glass should be used.

MAGNETIC PARTICLE INSPECTION (MT)

The inspection should be done in accordance with a recognized procedure,
e.g. ASTM E 709.
The test surface must be free from loose rust scale and moisture. An even paint layer
may be left in place over the inspected surface, providing that the thickness does not
exceed 100µm (3.94 mils).
Note! If there is any doubt that the paint coating is affecting the test results, it must
be removed from the inspection area.
Heavy grinding, brushing, or blasting may affect the results of this testing method in
some instances.
A magnetic field can be applied to the test material using one of the following
methods:
1. A permanent magnet.
2. A yoke which includes an electro-magnetic device.
 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 116

ULTRASONIC TEST (UT)

The testing should be done in accordance with approved standard methods.
Before this method can be used, the surface must be prepared to the required
flatness and smoothness conditions.
The scanning can be done using suitable direct and / or angled probes.
The inspection results should provide detailed information about any defects within
the volume of the weld, in addition to any surface cracks.

REPORTING PROCEDURE
Every detected crack or indication of an internal defect must be reported! When a
crack or defect is found, a repair is always necessary.
The owner of the crane is responsible for keeping complete records of all inspections.
Where defects are found, the owner must ensure that the repair is made. The
complete history of all defects, repairs and subsequent re-inspections must be
maintained for the full operational life of the crane.
The manufacturer should receive reports of the results of any structural inspection for
comparison with other similar structures throughout the world.
In particular, these should include photographs or sketches showing indications of
defects if any are evident, stating the following:
1. Location - right hand side, left hand side, north, south, east, west, etc.
2. Size of defect.
3. Extent of defect
a) In the toe of the weld.
b) Propagating into the base metal.
c) Any other notes.
4. Method of testing.
 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 117

FREQUENCY OF INSPECTION

End of Year Inspection

1-4 Visual inspection of all welds, bolted joints and surface coatings at
the end of the first year after start-up, and after each succeeding
(see note 1)
year. This includes the welds that are subject to NDT on certain
years.
5 After five years since start-up, the first full-scale NDT of welds must
be carried out. The inspection schedule lists the welds that are
subject to this requirement. All other welds, box type beams and
surface coatings are subject to a visual inspection.
Bolted joints are subject to torque tightening.
6 - 14 Visual inspection of all welds, bolted joints and surface coatings
after each succeeding year. This includes the welds that are
(see note 1)
subject to NDT on other years.
15 The full-scale NDT is repeated ten years after the first one. All
other welds, box type beams and surface coatings are subject to a
visual inspection.
Bolted joints are subject to torque tightening.
16 - 24 Visual inspection of all welds, bolted joints and surface coatings
after each succeeding year. This includes the welds that are
(see note 1)
subject to NDT on other years.
25, 30, etc. The full-scale NDT is carried out after 25 years, and then repeated
every five years. All other welds, box type beams and surface
coatings are subject to a visual inspection.
Bolted joints are subject to torque tightening.
26 - 29, etc. Visual inspection of all welds, bolted joints and surface coatings
(see notes 1, 2) after each succeeding year. This includes the welds that are
subject to NDT on other years.
Note 1. If the visual inspections give reason to suspect excessive crack growth,
additional NDT inspections must be carried out. These additional test
requirements are restricted to the specific welds that are showing crack
growth.
Note 2. After 25 years since start up, the NDT results for some weld details may
show that there are a significant number of new cracks since the previous
NDT inspection. This will occur if the stress levels in these details are close
to the maximum allowable. For these welds, the NDT must be repeated
every year, for the remaining life of the crane.
Note 3. For the bolted joint inspection schedule see the paragraph “Inspection and
Tightening of Bolted Joints” later in this Chapter.
 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 118

INSPECTION FOR FATIGUE CRACK GROWTH

Welded steel structures always contain small un-detectable cracks, usually at welded
joints. When these joints are subject to fluctuating stresses beyond a very small
value, the cracks grow. This is called fatigue crack growth.
The allowable stress levels used in the design of the structure, take this phenomenon
into account. The allowable stress levels are determined by analyzing laboratory
tests. Typical details are subjected to cycles of stress fluctuation. The allowable
stress level is determined by applying a factor of safety to the lower limit of the test
data scatter band. In a few laboratory tests, failure occurs at a stress level below the
allowable.
There are thousands of welded details in the crane structure, which are subjected to
repeated stress fluctuation. It is probable that fatigue crack growth will take place in
some details, before the end of full service life. This is a consequence of the
statistical nature of the phenomenon.
There are no recognized crane specifications used in the world today, that have
stresses at such a low level that fatigue crack growth will not be expected to occur on
a random basis. Eventually, the fatigue cracks will become large enough to be
detectable by means of non-destructive testing methods, i.e. dye penetrant, magnetic
particle or ultrasonic.
The use of very ductile steel by KONECRANES, ensures that cracks are detectable
by visual inspection, before fracture is likely. In many cases, even if fracture occurs,
the remaining elements of the structure will prevent serious damage, if the crane is
immediately taken out of service and repaired.
Periodic inspection is required to detect fatigue cracks that have grown to a
significant size, in order to avoid serious failure in the crane structure. When a crack
is found, a repair is necessary.
Restoring the structure to its original condition is always acceptable. Sometimes, this
is not practical, and a change in geometry by means of cutting and grinding is more
economic.
Sometimes, fatigue cracks are found with a frequency significantly greater than would
be expected, considering the stress levels used in the design. This may be caused by
over stress in the crane during its operation. If such cracking is found, a review of the
operation should be made, to see if over-stress is occurring. Remedial measures
should be developed to avoid it in future.
Cracking may also be due to differences in geometry between the actual detail and
the tested detail. In this case, it may be more economical to modify the geometry to
allow a smoother stress flow in the joints.
 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 119

INSPECTION FOR CORROSION

EXTERNAL CORROSION OF STEEL STRUCTURES

All steel structures are painted externally to prevent surface corrosion. Every year,
the external surfaces must be visually inspected to ensure that the paint coating is
intact.
In any areas where there is evidence of significant surface corrosion, the steel
thickness must be checked.

INTERNAL CORROSION OF BOX TYPE BEAMS

Even though the inspection hatches are tightly closed, some water may collect inside
large box type beams. This is due to the condensation of the humidity in the air
during daily ambient temperature cycles. The moisture may lead to the internal
corrosion of the box section beams.
The inside of all such beams must be visually inspected on a periodic basis, at the
same interval as the NDT tests. Where there is evidence of significant corrosion, the
thickness of the plate must be measured accurately.
When the inspection is completed, the access hatches must be re-fitted using new
seals.

MAXIMUM ALLOWABLE CORROSION OF STEEL STRUCTURES

The maximum allowable reduction in plate thickness varies between 5% and 15% of
the original thickness, mainly depending on the extent of the corroded area.
Any areas where the corrosion exceeds these levels must be repaired using an
acceptable procedure.
 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 120

REPAIR OF DAMAGES

REPAIR OF STRUCTURE AND WELDS

1. Inform the manufacturer of all structural repairs made to the crane.
2. If re-welding is proposed, the repairer shall satisfy himself that the weld repair to
the structure is practical. All repair procedures containing welding shall be
agreed with the manufacturer.

CAUTION !
No additional strengthening brackets or similar attachments may be welded to
the structure, without the written permission from the manufacturer.
Note! The arc welding current can damage anti-friction bearings. Always fix
the welding circuit return conductor directly to the structure being
welded and connect temporary large section earth conductors across
any anti-friction bearings that could be affected.
3. If a design modification is required, the manufacturer will forward the details and
the procedure, at the time of contact.

REPAIR OF SURFACE PAINTING

Any defective areas of the surface paint coating must be made good to the original
specification. This includes all areas where structural repairs have been made.
Before painting original damaged surfaces must be cleaned by hand or power steel
wire brushes to St3 cleanliness as per ISO 8051. Any dust, oil, grease and other dirt
shall be cleaned with suitable solvents and water.
Paint procedure shall be as follows (if not otherwise agreed with the customer):

Minimum Dry

Coat Product Color Film Thickness

First Zinc Epoxy Gray 40my/1.57mils

Second Epoxy Suppl. depend. 100my/3.94mils

Polyamide

Third Polyurethane Customer 60my/2.36mils

approved

Total dry film thickness 200my/7.87mils

 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 121

REPAIR OF INSIDE SURFACE COATING

The main girders and legs are sprayed completely from inside with the rust
preventing agent.
Any defective areas of the inside surface coating must be made good to the original
specification. This includes all areas where structural repairs have been made.
Before spraying original damaged surfaces must be cleaned by proper solvent and
hand or power steel wire brushes to St3 cleanliness as per ISO 8051.
Spraying procedure shall be as follows (if not otherwise agreed with the customer):

Minimum Dry

Coat Product Color Film Thickness

First Tectyl 506 or N/A 70my/2.76mils

Dinitrol 3641 E

Total dry film thickness 70my/2.76mils

REPAIR OF HOT DIP GALVANIZED PARTS

Before repairing original damaged surfaces must be cleaned by hand or power steel
wire brushes to St3 cleanliness as per ISO 8051. Any dust, oil, grease and other dirt
shall be cleaned with suitable solvents and water.

Repair procedure shall be as follows (if not otherwise agreed with the customer):

Minimum Dry

Coat Product Color Film Thickness

First High Zinc Epoxy Primer Silver Gray 40my/1.57mils

Second High Zinc Epoxy Primer Silver Gray 40my/1.57mils

Total dry film thickness 80my/3.15mils

 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 122

INSPECTION AND TIGHTENING OF BOLTED JOINTS

During the operation of the machine, the bolted joints are subjected to varying loads.
To minimize the differences in loads on these bolts, it is essential that they all remain
at a high and even tension.
In operation these bolts may become loose through settling of the joint surfaces.
The purpose of the periodic bolt tightness check is to make sure that all bolts are
carrying an equal share of the loads, and to replace any elongated or suspect bolts,
before fatigue fracture occurs.
The maintenance work must be carried out while the crane is out of operation and the
spreader is not carrying any container.

FREQUENCY OF BOLT INSPECTION

Bolt inspection procedures are devided into two categories based on the
thoroughness: Visual Inspection and Bolt Tightening Procedure. Their frequencies
are given in the table below.

Inspection Action Time of Action [Years after start-up]

Visual Inspection Every Year
Bolt Tightening Procedure 5, 15, 25, 30, 35
Replacement of Bolts when required

VISUAL INSPECTION
At each yearly interval when the welded connections are subjected to visual
inspection, all bolted joints in the structure must also be visually inspected.
For each joint, the visual inspection should include the following checks:
1. The bolts and / or nuts are tight.
2. Any locking devices that prevent the bolts and / or nuts from coming loose are
fitted correctly.
3. There is no evidence of relative movement between the joint faces.
If a bolted joint fails any of these checks, the Bolt Tightening Procedure must be
applied to the whole joint, and after that the locking devices must be fitted.
If there is any doubt that a bolt is seized or thread-bound and hence is not applying
the force to the joint, the bolt must be replaced.

TIGHTENING OF BOLTS
At the intervals when the welded connections are subjected to NDT inspection, all
bolted joints in the structure must also be tightened to the required torque.
The tightening torque values can be converted to other common units, using the
conversion factors (1 N-m = 0.738 lb-ft = 0.102 kg-m).
For personnel access to these bolted joints, a safe and suitable temporary platform
must be provided.
All torque wrenches used must be calibrated regularly.
 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 123

TABLE - BOLT TIGHTENING TORQUES

The following bolt tightening torque values are used if no other instructions are given
in the drawing. Torque values are applicable to screws of strength class 8.8.

TIGHTENING TORGUE OF SCREWS

Screw M6 M8 M10 M12 M16 M20 M24 M27 M30 M36 M42
size
Torque 8 20 38 65 200 390 680 980 1350 2360 3700
(Nm)
Torque 6 15 28 48 147 287 501 722 995 1740 2727
(lb-ft)

BOLT TIGHTENING PROCEDURE (NEW JOINTS, NEW BOLTS

OR REPLACEMENTS), TORQUE WRENCH
Tightening procedure is as follows:
1. Check that the washers are exactly flat, and free of burrs and defects.
2. Clean the bearing surfaces in the structure for washers and check that the surfaces
are level.
3. Clean the bolts and nuts.
4. Set the washers so that bevelled side is against bolt head or nut.
5. Tighten the bolts first to 80% of the full pre-tightening value. In addition for the
flange joints: Start simultaneously on the opposite sides of the joint and proceed
as shown in the drawing “Bolt tightening sequence” later in this chapter for
tightening sequences, until the whole joint has been gone through.
6. Tighten the bolts to the full 100% pre-tightening value. In addition for the flange
joints: Start simultaneously on the opposite sides of the joint and proceed as
before as shown in the drawing “Bolt tightening sequence” later in this chapter for
tightening sequences, until the whole joint has been gone through.
 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 124

BOLT TIGHTENING CHECKING AND RETIGHTENING (OLD

JOINTS, EXCEPT FLANGE JOINTS), TORQUE WRENCH
The following instructions apply when checking all other bolts than flange
joint bolts (see separate instructions later in this section).
1. The joint must be as unloaded as practical and the crane must be out of
operation during the work.
2. Wipe off any dirt and peel off the paint on the nut (if any). Spray thin, oiled
corrosion release agent (CRC or equal) onto all of the nuts and washers. Let it
effect for 10-20 minutes.

3. Record the initial position of each nut by stamping the

nut and the structure next to the washer with checking
marks (M).
4. Apply a torque of 80% of the nominal value onto each
bolt.
5. Check turning of the nut: If the nut has turned, mark this M
bolt by paint or equal to be retightened later.
6. Replace the bolt, nut and washers if necessary.
7. Repeat the above steps 3 - 6 for all of the bolts in the joint.
8. Nuts which have turned must be retightened acc. to the above instructions “Bolt
Tightening Procedure (New Joints, New Bolts or replacements), Torque
Wrench”.
9. Also nuts which have not turned must be retightened by following method bolt
by bolt:
10. First loosen the nut by turning it 30 degrees.
11. Retighten the nut by the full 100% pre-tightening torque.
12. Wipe off dirt and clean the black uncoated bolts and nuts with the proper
solvent and repaint acc. to instructions “REPAIR OF SURFACE COATING”
mentioned earlier in this Chapter.
 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 125

BOLT TIGHTENING CHECKING AND RETIGHTENING (FLANGE

JOINTS), TORQUE WRENCH
1. The following instructions apply when checking the flange joint bolts.
2. The joint must be as unloaded as practical and the crane must be out of operation
during the work.
3. Wipe off any dirt and peel off the paint on the nut (if any). Spray thin, oiled
corrosion release agent (CRC or equal) onto all of the nuts and washers. Let it
effect for 10-20 minutes.

4. Record the initial position of each nut by stamping the nut

and the structure next to the washer with checking
marks (M).
5. Apply a torque of 80% of the nominal value onto each bolt.
6. Check turning of the nut: If the nut has turned, mark this
bolt by paint to be replaced. M
7. Repeat the above steps 3 - 5 for all of the bolts in the joint.
8. Count how many bolts are marked to be replaced.
9. If more than 20% of the nuts in the joint have been marked, all of the bolts and
nuts in the joint must be replaced by new ones. See instructions “Bolt and Nut
Replacement of Flange Joint” in the next section.
10. If less than 20% of the nuts in the joint have been marked to be replaced, the
marked bolts and also one nearest bolt on either side of the marked ones must
be replaced by new ones. See instructions “Bolt and Nut Replacement of
Flange Joint” in the next section.
11. Also mark these adjacent bolts by paint to be replaced!
12. Nuts which have turned and replaced must be retightened acc. to the procedure
“Bolt Tightening Procedure (New Joints, New Bolts or replacements), Torque
Wrench”.
13. Also nuts which have not turned must be retightened by following method bolt by
bolt:
14. First loosen the nut by turning it 30 degrees.
15. Retighten the nut by the full 100% pre-tightening torque.
16. Wipe off dirt and clean the black uncoated nuts with the proper solvent and
repaint acc. to instractions “REPAIR OF SURFACE COATING” mentioned
earlier in this Chapter.
 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 126

BOLT AND NUT REPLACEMENT OF FLANGE JOINT (WHEN

REQUIRED)
All of the bolts used in a replacement job must come from a single production batch.
This is to guarantee uniform friction properties for the tightening.
Make sure that there is sufficient number of new nuts, bolts and washers to replace
all of those that must be changed at the same time. These replacements must be to
the correct design / strength and made from the correct material.
Carry out the check procedures for the fitting material, as described in the items 1 to
3 of Initial Tightening.
Slacken the marked bolts in the joint, bolt by bolt by fitting a new bolt immediately
after removing an old one. For the replacement procedure, it is essential that only
one bolt and nut are slackened and removed from the joint at any time.

Tighten each new bolt immediately after fitting to an 80% of the full pre-tightening
value.
Damage deliberately each removed bolt to prevent its reuse!
After replacing all of the marked bolts, tighten the bolts to full 100% torque following
the tightening sequence of the particular joint.

BOLT TIGHTENING SEQUENCE - MAIN GIRDER TO LEG JOINTS

Bolt and Nut Size 80% Tightening Torque Full Tightening Torque
M20 328 Nm (242 lb-ft) 410 Nm (302 lb-ft)

45 37 29 23 26 32 40 48

49 52
15 7 1 4 10 18
41 19 22 44

33 11 14 36

27 5 6 28

35 13 12 34

43 21 20 42
17 9 3 2 8 16
51 50

47 39 31 25 24 30 38 46

Note1 !
Bolts 1 - 22 are inside the structure. The maintenance hatch covers on top of the
main girder must be opened to gain access to these bolts. Make sure that each hatch
cover is closed tight after the joint checks are completed.
For this joint, there are always 3 adjacent bolts, which must also be replaced, if a bolt
has failed the acceptance test. These are the bolts on either side of the failed one
and the nearest bolt at the other side of the structure wall. For example, if bolt 2 has
failed, bolts 3, 8 and 24 must also be replaced. Similarly, if bolt 30 has failed, bolts
24, 38 and 8 must also be replaced.
 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 127

BOLT TIGHTENING SEQUENCE - LOWER LEG JOINTS (IF ANY)

Bolt and Nut Size 80% Tightening Torque Full Tightening Torque
M20 328 Nm (242 lb-ft) 410 Nm (302 lb-ft)

45 37 29 23 26 32 40 48

49 52
15 7 1 4 10 18
41 19 22 44

33 11 14 36

27 5 6 28

35 13 12 34

43 21 20 42
17 9 3 2 8 16
51 50

47 39 31 25 24 30 38 46

Note 1:
The same instructions apply also for the “lower leg joints” as for the “main girder to
leg joints” (above).

Note 2:
To gain access to some of the bolts, the cover plates for the cableways may need to
be removed. Make sure that these cover plates are replaced when the checks are
completed
 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 128

STRUCTURAL INSPECTION PLAN

INTRODUCTION
The structural inspection plan is in the form of drawings, showing the details of the
welds and the bolted joints to be inspected.
For convenience, the inspection plan is divided into sub-sections. These correspond
with the principal parts of a RTG Crane :
1. Leg Frames
2. Main Girders
3. Bogies
4. Trolley
5. Head Block
6. Diesel

Each of these sub-sections starts with a plan drawing. These general plan drawings
show the locations that are covered by the detail drawings.

TROLLEY

MAIN GIRDERS

LEG
FRAMES

DIESEL HEAD BLOCK

BOGIES
 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 129

INSPECTION OF MULTIPLE COMPONENTS

In many cases, the inspection plan location drawings may highlight only one or two
instances of a component detail. However, the same detail may be repeated many
times in the structure of the crane.
This does not mean that only the highlighted examples must be inspected.
The inspection plan applies to all instances of a similar detail.
Similarly, for clarity, the detail drawing may show only one end of a symmetrical
component.
The inspection plan applies to both ends of the component.

1.1

1.4
1.1

VT
1.2

VT

1.3
VT

VT
Steel Structure Location Drawing 1 Location Drawing 1.1
Leg Upper Flanged Joint
Inspection Locations in Leg Frames
Note! The bolt tightness for this structural
joint must be checked every year.
The detailed procedure is given in a
separate section of this manual.
 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 130

VT
VT

VT
VT

VT VT

VT

Check that each locating key is securely

bolted in position for all structural pins!

Location Drawing 1.2 Location Drawing 1.3

Leg Lower Flanged Joint Attachment Bracket for Diagonal Bracing
Note
The bolt tightness for this structural joint
must be checked every year. The detailed
procedure is given in a separate section of
this manual.
 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 131

VT
VT

VT

Check that each locating key is securely

bolted in position for all structural pins!

Location Drawing 1.4

Attachment Bracket for Horiz. Bracing
2.1

2.1

Main Girder Location Drawing 2

Inspection Locations in Main Girders

VT

Location Drawing 2.1

Web Plate Below Rail
RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 132

CHECK PIN LOCATING KEYS!

3.1

3.3

3.2
3.3
Bogie Location Drawing 3
Inspection Locations in Bogie

B B

UT 100%
B-B
A-A

UT 100%

Location Drawing 3.1

Gussets in Balancing Beams
RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 133

Items / RTG
96 pcs wheel nuts (M22)
48 pcs hub bolts (M21)

Tightening Torques
M22 - 500 Nm (369 lb-ft)
M21 - 65 Nm (48 lb-ft)

NOTE: CHECK ALL BOLTS

AND WHEEL NUTS.

Location Drawing 3.2

Wheel Nuts and Axle Bolts
Items / RTG
32 PCS Steering Lock
Mounting Bolts (M12)

32 PCS Steering Bearing

Flange Bolts (M12)

Tightening Torque for both

65 N-m (48 lb-ft)

NOTE: CHECK ALL BOLTS

Location Drawing 3.3

Steering Bearing and Lock Bolts
RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 134

4.4
4.5 4.6

4.3

4.2

4.1 4.1

4.2
Trolley Location Drawing 4
Trolley Inspection Locations

VT VT

VT

Location Drawing 4.1

Trolley Frame Welds
 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 135

Items / RTG
12 PCS supporting Frame to
Trolley Bolts (M6)

4 PCS supporting Frame to

Cab Bolts (M20)

Tightening Torques
M6 - 8 Nm (6 lb-ft)
M20 - 100 Nm (74 lb-ft)

NOTE: CHECK ALL BOLTS

AND PIN LOCATING KEYS
Location Drawing 4.2
Cab Support Frame Bolted Joints

CHECK ALL BOLTS! Items / RTG

24 PCS Trolley Frame to
Carriage Bolts (M16)

Tightening Torque
295 Nm (218 lb-ft)

NOTE 1: CHECK ALL

BOLTS

NOTE 2: BOLT GRADE

DIN931-10.9

CHECK ALL BOLTS!

Location Drawing 4.3

Trolley Frame to Carriage Bolted Joints
 RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 136

Items / RTG
- 24 PCS Auxiliary Winch
Mounting Bolts Bolts (M16)
- 16 PCS Moment Shaft
Mounting Bolts (M12)
- 4 PCS Moment Shaft to
Winch Bolts (M20)
- 12 PCS Clamp Bolts for
Auxiliary Rope (M16)
- 8 PCS Moment Shaft to
Winch Bolts (M6)
Tightening Torques
M6 - 8 Nm (6 lb-ft)
M16 - 210 Nm (155 lb-ft)
M12 - 65 N-m (48 lb-ft)
M20 - 50 N-m (37 lb-ft)

NOTE: CHECK ALL BOLTS

Location Drawing 4.4
Auxiliary Winches
Items / RTG
8 PCS Pedestal Mounting
Bolts (M20)
4 PCS Drum Shaft Key Bolts
(M16)

Tightening Torques
VT VT M20 – 410 Nm (302 lb-ft)
M16 – 210 Nm (155 lb-ft)

NOTE: CHECK ALL BOLTS

AND DRUM SHAFT
LOCATING KEYS.

Location Drawing 4.5

Trolley Frame Below Hoist Drum Supports
RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 137

Items / RTG
8 PCS Hoist Machinery
Mounting Bolts (M24)
Tightening Torques
M24 - 710 Nm (524 lb-ft)

NOTE: CHECK ALL BOLTS

VT VT
Location Drawing 4.6
Trolley Frame Below Hoist Machinery

Items / RTG
8 PCS Cable Basket
Mounting Bolts (M12)
16 PCS ACM Rope Pulley
Axle Holder Bolts (M16)
16 PCS Hoist Rope Pulley
Axle Holder Bolts (M20)
Tightening Torques
M12 - 65 Nm (48 lb-ft)
M16 – 200 Nm (147 lb-ft)
M20 – 390 Nm (287 lb-ft)

NOTE: CHECK ALL BOLTS

Location Drawing 5
Head Block Bolts
RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 138

Items / RTG
VT
VT 4 PCS Hoist Rope Pulleys
4 PCS ACM Rope Pulleys

VT

Location Drawing 5.1

Head Block Rope Pulley Welds

Items / RTG

VT VT
4 PCS Hoist Rope Pulleys

Location Drawing 5.2

Hoist Rope Pulley Frame Welds
RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 139

Items / RTG
VT
4 PCS Cable Basket Fixing
Plate
4 PCS Middle Beam to End
Frame

Location Drawing 5.3

Head Block Frame Welds

Items / RTG

4 PCS ACM Rope Pulley

Frame
4 PCS Hoist Rope Pulley
Frame

VT
NOTE: CHECK ALL WELDS
Location Drawing 5.4
Rope Pulley Frame Welds
RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 140

Items / RTG
Check 4 PCS Twistlock Pin
threads that there are no
cracks (or other faults). Then
clean and lubricate the parts.
Check 8 PCS M6 Twistlock
Mechanism Linkage Joint
fixing bolts.
Check 8 PCS M8 Twistlock
Mechanism Linkage to
Twistlock Nut Key fixing bolts.
Check 4 PCS M10 Twistlock
Limit Switch Bracket fixing
bolts.
Check 8 PCS M12 Twistlock
Mechanism Linkage to
Twistlock Nut fixing bolts.
Tightening Torques
M6 – 8 Nm (6 lb-ft)
M8 - 20 Nm (15 lb-ft)
M10 – 38 Nm (28 lb-ft)
M12 - 65 Nm (48 lb-ft)
NOTE: CHECK ALL BOLTS
Location Drawing 5.5
Twistlock Mechanism

Items / RTG
Measure 4 PCS Twistlock Pin
heads. The drawing shows
where the heads wear. When
the worn part exceeds the
area indicated by hatching
the twistlock should be
replaced. Minimum dimension
L = 25 mm.
Check the damege of the
head.
L

Location Drawing 5.6

Twistlock Wear limits
RTG Maintenance Vol 2 – Special Procedures – Structural Inspection 141

Items / RTG
Check welds of the frame
Check 4 PCS M24 Diesel
Frame to Sill beam fixing
bolts.
VT
Tightening Torques
M24 – 680 Nm (501 lb-ft)

VT
Location Drawing 6
Diesel Frame Welds and Bolts
 RTG Maintenance Vol 2 – Special Procedures – End Carriage Alignment 143

B. END CARRIAGE & RAIL WHEEL

ALIGNMENT
READ THIS FIRST
WARNING ! Prior starting the alignment work of end carriages or
rail wheels the safety information at the beginning of
this manual must be observed.

ALIGNING EQUIPMENT
1. Theodolite 6. Spring balance
2. Measuring sticks with magnet base 7. Plumb line 2 pcs.
(calibrated 4 pcs.) 8. Set of hand tools
3. Levelling instrument 9. Alignment protocol
4. Precision water level 10. Supporting bar for base line
5. Measuring tape 2 pcs, according to rail gauge
 RTG Maintenance Vol 2 – Special Procedures – End Carriage Alignment 144

ALIGNING PRINCIPLES OF THE WHEELS

STRUCTURE
Note! It is prohibited to hit the adjustable clamp (9) when adjusting the rail wheel.

1. Rail wheel 9. Adjustable clamp

2. Bearing housing (eccentricity 1.5 mm) 10. Bolt
3. Bearing housing cover (threaded ± 3 mm) 11. Washer
4. Shaft 12. Bolt
5. Sleeve 13. Washer
6. Grease nipple 14. Locking screw
7. Spherical roller bearing 15. Axial sealing
8. Bearing housing cover (threaded ± 3 mm) 16. Locking screw (axial direction)

EFFECTIVENESS OF ADJUSTMENT ACHIEVED BY

THE ECCENTRICITY
The bearing housing surfaces in the rail wheel boxes, are machined 1.5 mm out of
the rail wheel center line, in different directions. The bearing housing surface on the
outer side of the rail wheel box, is machined 1.5 mm out of the rail wheel center line
in the vertical direction, and the bearing housing surface on the inner side of the rail
wheel box, is machined 1.5 mm out of the rail wheel center line in the horizontal
direction. According to this, the wheel base is 3 mm shorter on the inside of the end
carriage, than on the outside. The eccentric bearing housings compensates the
center line of the wheel shaft back to correct position.
When aligning the end carriage, the bearing housings should not be turned more
than 45°, because if they are turned more, then the other direction will change more
than the intended.
 RTG Maintenance Vol 2 – Special Procedures – End Carriage Alignment 145

VERTICAL ALIGNMENT
1. End carriage 2. Bearing housing 3. Rail wheel

The highest spot of the eccentricity in the bearing housing, is marked with two dots =
starting position. Vertical inclination is adjusted by turning the inner bearing housing.
By turning the bearing housing 1 the inclination will be changed about 0.1 mm/m.
 RTG Maintenance Vol 2 – Special Procedures – End Carriage Alignment 146

Allowed vertical inclination

Inwards (-) : - 0.5 mm/m
Outwards (+) : + 2.0 mm/m

HORIZONTAL ALIGNMENT
1. End carriage 2. Bearing housing 3. Rail wheel

The highest spot of the eccentricity in the bearing housing, is marked with two dots =
starting position. Horizontal direction is adjusted by turning the outer bearing housing.
By turning the bearing housing 1 the angular deviation will be changed about 0.1
mm/m. Allowed horizontal divergence: ± 0.4 mm/m.
 RTG Maintenance Vol 2 – Special Procedures – End Carriage Alignment 147

AXIAL ADJUSTMENT
1. End carriage 2. Bearing housing 3. Rail wheel 4. Threaded bearing cover

Axial direction is adjusted by turning the threaded bearing covers on both side of the
wheel. Max. rail wheel adjustment is ± 3 mm.
Note! The threaded bearing covers may not be tightened, only turned slightly
against the bearing. There must be left an axial clearance of 0.3 ... 0.5 mm.
Allowed sequence of rail wheels rolling on a common rail is ± 1 mm.

FINAL MEASUREMENTS
The final measurement is made from the marking groove side of the rail wheel, using
just one measuring stick, except from the wheel sequence measurement, where two
measuring sticks are used.

MEASUREMENT OF RAIL WHEEL VERTICAL DIRECTION

1. Fasten the measuring stick on the upper measuring point (1) of the rail
wheel, check the reading and write it down
2. Move the measuring stick to the lower measuring point (2), check the reading
and write it down
 RTG Maintenance Vol 2 – Special Procedures – End Carriage Alignment 148

1. Measuring stick 2. Measuring stick

Measuring points 1, 2, 3, 4 Measuring point 2

Calculate from the readings of the measuring sticks, whether the inclination of the
wheel is according to the given tolerances - 0.5 ... + 2.0 mm/m. It is not
recommended for the inclination to be on the - side.

MEASUREMENT OF RAIL WHEEL HORIZONTAL DIRECTION

1. Fasten the measuring stick on the horizontal measuring opening (3) of the
rail wheel, check the reading and write it down (A.)
2. Move the measuring stick to the other horizontal measuring point (4), check
the reading and write it down (B.)

A. B.
1. Measuring stick, Measuring opening 3. 1. Measuring stick, Measuring point 4
3. Calculate from the readings of the measuring sticks, whether the direction of
the wheel is according to the given tolerances ± 0.4 mm/m.
4. If the direction of the wheel is not according to the given tolerances, correct
the direction according to the instructions given in Figure 5.
 RTG Maintenance Vol 2 – Special Procedures – End Carriage Alignment 149

5. Make the measurements to the other wheel of the end carriage, according to
the instructions given in Chapter.

MEASUREMENT OF RAIL WHEEL SEQUENCE

Fasten the measuring sticks on the
horizontal measuring openings (3), and
check with the theodolite, that the sequence
of the rail wheels is ± 1 mm
If the sequence of the rail wheels is not
according to the given tolerances, correct
the sequence according to the instructions
given in chapter

1. Measuring stick
Measuring opening 3

SPAN MEASUREMENT
1. Drop the plumb lines to the floor from the inside of one of the rail wheels, and
from the outside of the other rail wheel.
2. Measure span along the floor to avoid the error caused by the sag of the tape
measure.

The allowed divergence of the span

The greatest divergence of the crane span (s):
If span is less or equal as 15 m, then the maximum divergence is ± 2 mm.
If span is longer than 15 m, then the maximum divergence is:
± [ 2 + 0.15 ( s - 15 ) ] mm, (max ± 15 mm) (s is to be expressed in m).
 RTG Maintenance Vol 2 – Special Procedures – Rope Change 151

C. ROPE CHANGE
TABLE – ROPE DATA

HOIST ROPE INFORMATION

Quantity Rope Type (galvanized) Min. Breaking Diameter in
Force (kN) mm
2 26 ZBB 6x36WS-IWRC-1960-SZ 472 26.0
or 2 1” ZBB 6x36WS-IWRC-1960-SZ 25.4 (1 inch)
2 26 ZBB 6x36WS-IWRC-1960-ZS 472 26.0
or 2 1” ZBB 6x36WS-IWRC-1960-ZS 25.4 (1 inch)
Height Lifting Height in Meters (feet) Rope Length in mm (inch)
1 over 4 15.24 m (50’) 45000 (147’- 7 5/8”)
1 over 5 18.10 m (59’- 4 5/8” ) 49000 (160’- 9 1/8”)
1 over 6 21.00 m (68’- 10 3/4”) 56000 (183’- 8 3/4”)

AUXILIARY ROPE INFORMATION

Quantity Rope Type (galvanized) Min. Breaking Diameter in
Force (kN) mm
2 16 ZBB 6x36WS-IWRC-1960-SZ 179 16.0
or 2 5/8” ZBB 6x36WS-IWRC-1960-SZ 15.9 (5/8 inch)
2 16 ZBB 6x36WS-IWRC-1960-ZS 179 16.0
or 2 5/8” ZBB 6x36WS-IWRC-1960-ZS 15.9 (5/8 inch)
Height Lifting Height in Meters (feet) Rope Length in mm (inch)
1 over 4 15.24 m (50’) 47000 (154’- 2 3/8”)
1 over 5 18.10 m (59’- 4 5/8” ) 51000 (167’- 3 7/8”)
1 over 6 21.00 m (68’- 10 ¾”) 58000 (190’- 3 1/2”)

ROPE CLAMP INFORMATION

Bolt Tightening of Rope Clamps Torque
Clamps for Hoist Ropes on Hoist Drums (M24) 332 lb-ft (450 Nm)
Clamps for Auxiliary Ropes on Winch Drums (M16) 155 lb-ft (210 Nm)
Clamps for Auxiliary Ropes on Hoist Drums (M16) 155 lb-ft (210 Nm)
NOTE: The procedures in this section are applicable to all steel wire ropes.
 RTG Maintenance Vol 2 – Special Procedures – Rope Change 152

PROCUREMENT OF ROPES
Note! The hoist ropes on an RTG crane must always be replaced as a complete set
of four new ropes. Never replace only one hoist rope! The stretch characteristics of
the new ropes are not the same as the old ones that have been in use for a period of
time, even if they are supplied from the same original drums of new rope.

ROPE TYPE & STRENGTH

The technical data for the original ropes is detailed in the Rope Data Table. The
specification for the replacement ropes should match this data.
Although the design of the crane is based on standard metric rope sizes, equivalent
ropes to imperial sizes may also be used, providing that they meet this specification.
In particular, with hoist ropes the minimum breaking force must not be less than the
original specification which is based on FEM standards.

ROPE MATCHING
From the data table at the top of this page, it can be seen that two of the hoist or
auxiliary ropes have a lay in one direction and the other two ropes have a lay in the
opposite direction. This is important for the smooth winding of the ropes into the
helical grooves of their hoist drums.
When new rope is required, these two different types of rope should be purchased at
the same time as matched ropes.
With hoist ropes it is important that the two different lays of rope should be made to
exactly the same specification because this also affects their stretch characteristics.

PREPARING THE ROPE

TRANSPORTATION DRUMS
Before a new wire rope is ever taken off a drum, the drum must always be mounted
on an axle which allows the free rotation of the drum.

This can be either a horizontal bar mounted between two axle stands, or a special
capstan with a vertical axis.
The drum will then rotate to allow the rope to be pulled off, without introducing twists
or kinks into the rope.
Under no circumstances should a wire rope be un-coiled from a stationary drum.
Whenever rope is put back onto a drum, the drum should always be rotated to coil
the rope, without introducing twists or kinks into the rope.
Under no circumstances should a wire rope be coiled onto a stationary drum.
 RTG Maintenance Vol 2 – Special Procedures – Rope Change 153

PULLING & JOINTING SOCKS

Fit temporary binding here

The simplest attachment that can be fitted to the end of a wire rope to pull it from a
drum is to use a pulling "sock".
The sock consists of a length of steel braid, which is fitted over the end of the wire
rope. A temporary binding is then made around the open end of the braid, to hold it
against the wire rope. When the loop on the other end of the sock is pulled, the braid
tightens around the wire rope and forms a secure attachment.
So that the correct tightening occurs, it is important that the size of pulling sock is
matched to the diameter of the wire rope. The sock attachment length "L" must not
be less than the minimum specified by the sock manufacturer.
When the pulling tension is released from the loop, the sock can be taken off the end
of the wire rope. The temporary binding must first be removed, and then the braid
can be slid off the wire rope.

A temporary jointing sock uses two pulling socks, which are directly connected
together. Each end is attached to the wire rope in exactly the same way as for a
single sock.
Note A temporary jointing sock can only be used between two wire ropes with
similar diameters. When a small diameter pulling rope is being used, this
should be attached to the loop of a single pulling sock.

CUTTING TO LENGTH
When ropes are supplied for a particular application, it is preferable that they are
supplied pre-cut to the correct length.
If not, each rope should be cut to the correct length, before installation on the
Unloader
From an axle mounted drum, the correct length of rope should be run out and be
supported on rollers or blocks of wood, placed at regular intervals along a clean level
surface.
The ropes must not be dragged along an abrasive surface.
Two bindings should then be made around the rope, at either side of the position
where the rope is to be cut. Bright steel wire should be used for these bindings.
Note that these bindings should always be applied to a rope before it is cut, to
prevent the new ends from fraying.
 RTG Maintenance Vol 2 – Special Procedures – Rope Change 154

Cut Here

The rope should be cut using a purpose designed guillotine, to ensure a clean cut.
If a guillotine is not available, additional temporary bindings must be added at the
position of the cut, before any sawing. This will support the individual wires, and
prevent the ends from splaying.
After cutting, any permanent fitting should be attached to one end of the rope, using
the correct procedure.
The rope should be wound back onto the drum, before installation on the Unloader.
The end with any permanent fitting must be securely clamped onto the drum first.
The rope is then wound onto the drum, so that the outer end has no fitting. The free
end should be secured, so that the turns cannot become loose during transportation.

WEDGED HEAD FITTINGS

Wedged head fittings are used on the ends of wire ropes in situations where the
assembly has to be made after the rope is threaded around the pulleys.
The fitting can also be released from the rope at any time, to permit adjustments in
the length of the rope.

WEDGE ASSEMBLY PROCEDURE

The stages of the assembly procedure are shown in the following sketches:

1. With the wedge removed, the end of the wire rope is threaded through the
fitting.
2. The wire rope is made into a loop, and the free end is passed back through the
fitting.
Note The main part of the wire rope must be at the correct side of the fitting,
with its axis aligned with the holes for the attachment pin.
3. The wedge is positioned inside the loop in the wire rope. The loop and the
wedge are then pulled into the fitting, until the assembly becomes tight.
4. A grip is fitted onto the free end of the wire rope. This prevents the fitting from
coming apart, when the main part of the wire rope is slack.
Note The grip must only be fitted onto the free end, and must not be fitted to
the main part of the wire rope.
 RTG Maintenance Vol 2 – Special Procedures – Rope Change 155

ADJUSTMENT PROCEDURE
The adjustment procedure is as follows:
1. The grip is removed from the free end of the wire rope.
2. The wire rope is pushed into the fitting, to release the wedge. The loop can then
be adjusted by moving the free end of the rope relative to the main part.
3. The loop and the wedge are pulled back into the fitting, until the assembly
becomes tight again.
4. The grip is re-fitted onto the free end of the wire rope.

SAFETY PRECAUTIONS BEFORE ROPE CHANGE

READ THIS FIRST

WARNING ! Read the following safety preacautions prior
starting changing the rope.

Gantry Parking Before changing the ropes, the gantry of the RTG crane
should be positioned at a suitable level location, away from
any container stacks.
Sufficient clear space must be available at ground level for
laying out the ropes.
Trolley Traverse For the safe access to the hoist (and winch drums), the
Position trolley should be at the normal parking position, where the
main girders have additional hand-rails for personnel
protection.
Spreader Resting on Before any rope changing, the spreader must be retracted to
the Ground minimum length and lowered so that it is resting on suitable
blocks of wood at ground level.
Isolation of Gantry While the rope changing is in progress, the gantry travel and
Travel and Trolley trolley traverse drives must be prevented from being
Traverse Drives operated. The electrical supplies to all of these drives must
be isolated (in the Electrical Equipment Room).
 RTG Maintenance Vol 2 – Special Procedures – Rope Change 156

LOCAL CONTROL OF HOIST DRIVES

READ THIS FIRST

WARNING ! While the crane is selected to Maintenance Mode,
the slow-down and stop limit switches for the hoist
drives are by-passed in the PLC.
Other safety interlocks such as the overload
protection are also by-passed.

LOCAL CONTROL PUSH-BUTTONS

For the convenient operation of the two hoist drives during this maintenance work,
the push-button local control should be fitted (see separate section of this manual).

CRANE IN MAINTENANCE MODE

To permit the operation of the hoist drives using the local control push-buttons, the
RTG crane must be selected to "Maintenance Mode", by turning the key switch (in
the Electrical Equipment Room).

LOCAL CONTROL OF AUXILIARY WINCH DRIVES

For the convenient operation of the aux. winches during changing the aux. ropes,
each winch could be operated using its front panel or controls from cabin (see
separate sections in this manual).

TEMPORARY HOIST OR REEVING WINCH

While changing each hoist rope, the self-weight of each vertical length of a hoist rope
is typically 80-90 kg. This is too heavy to be held by hand and so the weight of the
rope between the trolley and the ground must be supported by other means.

TEMPORARY HOIST REEVING WINCH

A suitable temporary hoist must be used (ALTERNATIVE)
to support each length of a hoist rope As an alternative to using a temporary
while the old rope is lowered from the hoist (mounted on the trolley), a separate
trolley and the new one is pulled up. reeving winch can be used.
This hoist needs to be mounted at In this case, the winch is positioned at
various positions on the trolley, ground level and a temporary pulley is
convenient for the ends of each hoist mounted on the trolley to locate the
rope. A temporary pulley can also be reeving rope above the required positions
used to locate the rope from the of the hoist ropes.
temporary hoist in exactly the most
suitable positions.
 RTG Maintenance Vol 2 – Special Procedures – Rope Change 157

TEMPORARY REEVING ROPE (AUX. ROPES)

The self-weight of each vertical length of an auxiliary rope is typically 30-35 kg. While
changing each auxiliary rope, its weight between the trolley and the ground can be
supported by a hand-held reeving rope.
The reeving rope can made from synthetic material. This has the advantage of being
flexible and easier to handle.
While holding or lowering an auxiliary rope, turns of the reeving rope can be wrapped
around a convenient part of the trolley structure to provide addition support.

REMOVAL OF OLD ROPES

UNWINDING OF FRICTION TURNS (HOIST / AUX. ROPE)

With the spreader resting on the ground, carefully operate each hoist / aux. winch
drive to unwind the spare turns and the friction turns from its corresponding drum.
Stop each drum so that the hoist / aux. rope is unwound to just before the positions
of it’s clamps onto the drum. Do not go too far!
Note! While the old hoist / aux. ropes are being removed and the new ropes are
being reeved, the RTG hoist / aux. drives are not required. During this period, the
diesel alternator can be shut down if it does not supply power to the temporary hoist.

LOWERING OF HOIST ROPE - FIXED END

The following procedures should be repeated for each of the four old hoist ropes.

Location of Temporary Hoist

Mount the temporary hoist (or the temporary guide pulley) above the position
where the selected hoist rope is attached to the trolley.
RTG Maintenance Vol 2 – Special Procedures – Rope Change 158

Clevis
Pin
Attachment to Temporary Hoist
At a position about 0.3 m below the end fitting on the old
hoist rope, attach the end of the rope from the temporary
hoist. This can be done either by using a proprietary rope
reeving grip or by clamping the two ropes together with
suitable U-grips. Temporary
Supporting
Using the temporary hoist, take in any slack in its rope. Rope
Then, raise it by a small amount so that the full weight of
the old hoist rope is supported by the temporary hoist.

RELEASE OF ROPE END FITTING FROM THE

TROLLEY ATTACHMENT
Make sure that the there is no load on the end fitting of
the old hoist rope. Then, remove the clevis pin which Hoist
attaches the rope end fitting to the fixing point on the Rope
trolley (below its load cell).

Lowering of Old Hoist Rope / End Fitting

Using the temporary hoist, lower the end of the old hoist rope. Guide the old
hoist rope so that it lies "flaked" on the ground next to the end of the spreader.
When the attachment between the two ropes has been lowered to ground level,
release this attachment and then rewind the temporary hoist.
 RTG Maintenance Vol 2 – Special Procedures – Rope Change 159

LOWERING ROPES - DRUM ENDS (HOIST / AUX. ROPE)

EACH OLD HOIST ROPE HOIST OR WINCH DRUM EACH OLD AUX. ROPE
1. Locate the temporary WINCH DRUM END:
supporting rope above Rope Clamps 1. Attach the temporary supporting rope
the position where the onto Drum
at a position just below the winch
old hoist rope falls drum, onto the old auxiliary rope. This
vertically from the drum. can be done either by using a
2. Attach the temporary proprietary rope reeving grip or by
supporting rope using clamping an eye or hook onto the old
suitable clamps. auxiliary rope with suitable U-grips.

3. Take-in the slack of the Caution! Do not just tie the supporting
temporary supporting rope directly onto the auxiliary rope.
Temporary A rope clamp or other device must be
rope so that it holds the Supporting
weight of the hoist rope. Rope
attached to the auxiliary rope to prevent
it from sliding through the knot in the
4. Loosen the bolts of the supporting rope.
four attachment clamps
on the RTG hoist drum. 2. Make sure that the weight of the old
auxiliary rope is supported and then
5. Unwind the last turn of slacken the bolts of the four drum
the hoist rope from clamps. This releases the aux. rope
around the hoist drum. end from the winch drum.
Rope
6. Lower this end of the 3. Lower the end of the old auxiliary
hoist rope to the ground. rope to the ground. by using the
temporary supporting rope with two
7. Release the attachment turns around a suitable part of the
clamps from the trolley structure.
temporary supporting
HOIST DRUM END
rope.
The procedure for lowering the hoist
drum end of each old aux. rope is the
same as for the old hoist rope (left).

REMOVAL OF ROPE FROM HEAD BLOCK PULLEYS (HOIST /

AUX. ROPE)
When each old rope is resting on the ground, it must be withdrawn from its pulley on
the spreader head block.
With old hoist rope the end which includes the attached end fitting can be pulled
away from the spreader by attaching it to a suitable truck.

DISCARD OF ROPES (HOIST / AUX. ROPE)

It is important that old hoist ropes are never used again by mistake. To ensure this,
the old ropes should be cut-up into several shorter lengths.
These lengths of old rope can then be discarded into a suitable scrap disposal
system.
 RTG Maintenance Vol 2 – Special Procedures – Rope Change 160

INSTALLATION OF NEW ROPES

CORRECT LOCATIONS OF NEW ROPES (HOIST / AUX. ROPE)

It is important that the two types of ropes (with an opposite lay) are installed in the
correct positions on the crane.

Hoist Ropes
The diagram shows which hoist ropes
must have the "ZS" lay and which
must have the "SZ" lay.
ZS

SZ ZS SZ

Auxiliary Ropes
The diagram shows which auxiliary
ropes must have the "ZS" lay and
which must have the "SZ" lay.

ZS
SZ
ZS

SZ
 RTG Maintenance Vol 2 – Special Procedures – Rope Change 161

RAISING A NEW ROPE

This paragraph covers all procedures that are required for raising either end of a new
hoist or auxiliary rope (different set of procedures required).
All of these procedures are not required for raising the both types of ropes nor both
rope ends. Select the right procedure for right rope and right end from the selection
grid at the right side of the table (selected procedure is marked with black color).
For raising a new hoist rope:
- First, follow the column ‘Hoist Rope End’ – ‘Fixed’ (Fixed end of new hoist rope)
- Secondly, follow the next column ‘Hoist Rope End’ – ‘Drum’ (Hoist drum end of
new hoist rope)
For raising a new auxiliary rope:
- First, follow the column ‘Auxiliary Rope End’ – ‘Aux’ (Auxiliary Winch drum end of
new auxiliary rope)
- Secondly, follow the next column ‘Auxiliary Rope End’ – ‘Drum’ (Hoist drum end of
new auxiliary rope)
Action Description Hoist Rope Auxiliary
End Rope End
Fixe Drum Aux Drum
d
Fit Fit the drum of new rope onto a suitable drum
Drum stand next to the spreader. 1. 1.
Stand
Reeve Pick up the free end of the new aux. rope and
Aux. feed it the correct way through the
Rope corresponding pulley on the head block.
Through
Spreader
If necessary, a block of wood should be placed 2.
Pulley on the top of the head block to support the new
aux. rope. Do not allow the new rope to directly
rest on, or to be dragged over any fixed part of
the head block.
Locate Lower the temp. hoist or temp. reeving rope
Temp. from the position where the rope is to be
Hoist or attached.
Temp.
Each new rope should wind onto its drum at 2. 3. 1.
Reeving
Rope the side which is nearest to the centre line of
(Aux the trolley.
Rope)
 RTG Maintenance Vol 2 – Special Procedures – Rope Change 162

Action Description Hoist Rope Auxiliary

End Rope End
Fixed Drum Aux Drum
Attach
Temp.
Hoist
or
Reevin
g Rope
(With
aux. X
Rope)
Temporary
Supporting
Rope

New
Rope

At a position about ‘X’ (read value at right) from the end fitting
on the new rope, attach the supporting rope from temp. hoist
or reeving rope (with aux. rope). This can be done either by
X= X= X= X=
using a proprietary rope reeving grip or by clamping the two
0.3 m 2.8 m 1.4 m 2.8 m
ropes together with suitable U-grips.
(1 ft) (7 ft)* (4½ (7 ft)*
* Note! When raising hoist or aux. rope’s drum end make ft)
sure that the free end must be long enough to go about 1¼
turns around the hoist drum, so that it can be fitted under the
clamps.
Raise Using the temp. hoist (or rope) take up any slack in its
Rope rope. Then raise the temp. rope so that the new rope
End is...:
Hoist Rope Fixed End:
...pulled off from its supply drum and up to the trolley
level. Read ‘Hint’.
Drum End of Hoist or Aux. Rope:
... pulled through the pulley on the head block.
Continue hoisting until the free end of the new rope is
up to the drum level. 3. 1. 4. 2.
Winch End of Aux. Rope:
Haul up the temp. reeving rope so that the new aux.
rope is pulled off from its supply drum through the
pulley on the head block and up to the trolley level.
Read ‘Hint’.
Hint ! The rope lubrication is difficult to do when it is
hanging from the trolley. As the new rope is pulled
from the supply drum at ground level, it can easily be
lubricated with the correct type of grease.
 RTG Maintenance Vol 2 – Special Procedures – Rope Change 163

Action Description Hoist Rope Auxiliary

End Rope End
Fixe Drum Aux Drum
d
Attach With the weight of the new hoist rope supported
Rope End by the temp. hoist, re-fit the clevis pin which
4.
to Trolley attaches the rope end fitting to its fixing point on
the trolley (below its load cell).
Tightening Torque
Locate
X Free End
and
Clamp
Rope End
to Drum

2. 5. 3.

With the weight of the new rope held by the temp. supporting
rope bend the free end of the new rope around the drum for
about 1¼ turns. The end of the new rope must go sufficiently
beyond the position of the last clamp on the drum. X= X= X=
If necessary, adjust the free end position of the new rope by
operating the temp. hoist (with hoist rope). 450 210 210
Refit the drum attachment clamps onto the new rope. Nm Nm Nm
Make sure that the single turn of the new rope is wound or or or
tightly around the drum. 332 155 155
Then tighten the clamp bolts to the correct torque lb-ft lb-ft lb-ft
Note! The clamps for the hoist and aux. ropes are designed
so that each drum is statically balanced.
Do not replace those with clamps of a different design.
Release When the new rope is correctly attached to the
Temp. drum or trolley, slowly lower the temporary rope
Hoist or until its rope is slack. 5. 3. 6. 4.
Reeving Release the temp. attachment between the
Rope supporting rope and the new rope.
 RTG Maintenance Vol 2 – Special Procedures – Rope Change 164

Action Description Hoist Rope Auxiliary

End Rope End
Fixed Drum Aux Drum
Wind With the spreader resting on the ground,
Friction carefully operate corresponding drive to wind
Turns the friction turns onto its drum.
With Aux. Rope’s Drum End: Continue winding
until all slack is taken in for the hoist ropes (the
6. 7. 5.
aux. ropes should still be slack). Then operate
each aux. winch drive to wind the spare turns
onto its drum until there’s no slack in it’s rope.
Finally, for each hoist and aux. drum check that
the rope is lying correctly in its spiral groove.
Unwind The remaining length of the new rope must be
Remaining completely removed from its supply drum,
Length of before the free end can be reeved through the
New Rope pulley on the head block (with hoist rope) or
raised to the hoist drum (with aux. rope). This
can be done by pulling the rope into a single
loop.

This end suspended

from trolley (hoist
rope) or aux. winch
(aux. rope)

Free
End 7. 8.

To support this loop of new rope, suitable blocks of wood must

be placed on the ground at regular intervals. Do not allow the
new rope to rest on the ground.
When the new rope is lying in the correct position, its free end
should be resting next to the spreader.
 RTG Maintenance Vol 2 – Special Procedures – Rope Change 165

Action Description Hoist Rope Auxiliary

End Rope End
Fixed Drum Aux Drum
Reeve Hoist: Pick up the free end of the new hoist
New Rope rope and feed it the correct way through the
Through corresponding pulley on the spreader head
Spreader block.
Pulley
Note!
The fixed end of each hoist rope should be
from the outer end of its pulley on the
spreader head block. The end that
attaches to the hoist drum is always at the
inner end of its pulley on the spreader.
Aux: Fit the drum of new aux. rope onto a 8.
suitable drum stand, next to the spreader.
Pick up the free end of the new auxiliary
rope and feed it the correct way through the
corresponding pulley on the spreader head
block.
If necessary, a block of wood should be
placed on the top of the spreader head
block to support the new auxiliary rope. Do
not allow the new rope to directly rest on, or
to be dragged over any fixed part of the
head block.
Adjust the rope length, if necessary (next paragraph).
 RTG Maintenance Vol 2 – Special Procedures – Hoist Balance Adjustment 167

D. HOIST ROPE ADJUSTMENT

The following procedures require that each hoist drive is operated using the local
hand control. The diesel-alternator must also be running to provide the electrical
power.

TAKE UP SLACK
Carefully operate each RTG hoist drive (one at a time) to take up the slack in the
(new) hoist ropes, making sure that each rope is correctly located in its pulley on the
spreader head block.

WOODEN BLOCKS UNDER SPREADER

Continue raising each RTG hoist
drive until the spreader is just
clear of the ground.
Next, place 4 blocks of wood
below the spreader in the
positions shown in the diagram
and then lower the spreader onto
them.

ROPE IMBALANCE MEASUREMENT

Using the local control, raise one Longer Hoist Rope
RTG hoist until its end of the
spreader is just above the
ground. The other end of the
spreader should be resting on Height Difference 'Z'
only the one wooden block under
its end.
Measure the height difference
(‘Z’) between the two hoist rope
pulleys on the spreader head
block.
Also identify which of the two
hoist ropes is the longer one that
will need shortening.
Do this with both hoists.
 RTG Maintenance Vol 2 – Special Procedures – Hoist Balance Adjustment 168

ROPE BALANCE ADJUSTMENT

If the height difference (‘Z’) between the spreader pulleys in either hoist is greater
than 5 mm (0.2”) the rope balance must be adjusted.

UNWINDING OF FRICTION TURNS

With the spreader resting on the ground, carefully operate each hoist drive to unwind
the spare turns and the friction turns from its hoist drum.
Stop each drum so that the hoist ropes (and the auxiliary ropes) are unwound to just
before the positions of their clamps onto the drum. Do not go too far!

SHORTENING OF LONGER HOIST ROPE (EACH HOIST DRUM)

Rope Shortening
1. Mark the hoist drum at the initial end Distance 2 x 'Z'
position of the hoist rope to be
shortened.
2. Attach the supporting rope from a Initial Position
temporary hoist to hold the weight of the of Rope End
RTG hoist rope, as shown.
3. Slacken the four clamps on the RTG
hoist drum.
Temporary
4. Slowly raise the temporary hoist until the Supporting
end of the RTG hoist rope is located in Rope
the correct new position.
5. Re-tighten the rope clamps on the hoist
drum to the correct torque.
6. Release the temporary supporting rope.

Note! Remember that the rope shortening distance around the hoist drum is twice the
height that the spreader pulley must be raised.

ROPE BALANCE CHECK

Repeat the measurement procedures (8.1 to 8.3) to check the new balance between
the hoist ropes.
If necessary, repeat the adjustment procedures until the two hoist ropes on both hoist
drums are balanced to within the acceptable tolerance.
 RTG Maintenance Vol 2 – Special Procedures – Hoist Balance Adjustment 169

LIMIT SWITCH CHECKING / ADJUSTMENT

Once the new hoist ropes have been installed, the limit switches on each hoist must
be checked and adjusted to the correct operating positions, if necessary.

LOWER STOP LIMIT SWITCH (EACH HOIST)

Lower Stop Limit Switch Operating Position (hoist rope "friction" 2.0 turns
turns around the drum, not including the "clamped" turn)
Providing that each hoist drum was not turned between removing the old hoist ropes
and fitting the new ones, the lower stop limit switch should not need any adjustment.
The correct operating position for each of this limit switch can be checked by carefully
lowering the hoist drive and monitoring when the switch changes state.

WARNING ! The stop limit switch for each hoist is

by-passed when the crane is selected to
"Maintenance Mode".

During the normal operation of the crane, there must always be at least two "friction"
turns of hoist rope around each hoist drum. These friction turns significantly reduce
the loads on the drum clamps. Also, the hoist rope must not be unwound beyond the
end of its spiral groove on the hoist drum.
Note! When the crane is commanded from the Operator's Cab, the "slack rope"
detection may prevent the lowering of the hoists, before the stop limit
switches are reached.

UPPER STOP LIMIT SWITCH (EACH HOIST)

Upper Stop Limit Switch Operating Position 1000 mm

(top of spreader pulley distance below level of gantry rails) (39.37 inch)
 RTG Maintenance Vol 2 – Special Procedures – Hoist Balance Adjustment 170

INITIAL RAISING OF SPREADER

Before this limit switch can be set, the spreader must first be raised until it is
about 3 m (10 ft) below the trolley.
Caution! Do not raise the spreader from ground level to the fully raised
position, unless either the auxiliary winches are operating normally
or until the auxiliary ropes are slackened.

The spreader can be raised in maintenance mode by using the local control
push-buttons for the hoists and the inverter front panel controls for the auxiliary
winches.
1. Carefully operate each auxiliary winch to fully unwind its auxiliary rope.
(see separate section of this manual for operating instructions)
2. Raise both hoists until the spreader is nearly at the fully raised position.
Because only a single hoist drive can be operated at any one time, the two
drives must be operated alternately. Do not allow the trim difference between
the two hoists to become too large.
As another option, both hoist drives could be raised at the same time by using the
Operator's Cab controls (in normal mode). However, the auxiliary winches must also
be operating normally to prevent the overload of the auxiliary ropes.

UPPER STOP LIMIT SWITCH ADJUSTMENT (EACH HOIST)

1. Using the local control push-buttons, carefully raise the hoist so that the
pulleys on the spreader head block are the correct distance below the hoist
drum for the operating position of this limit switch.
Note!
If the hoist is already above this height, it must be lowered to below the
switch operating position and then raised to the required level. This avoids
any back-lash errors in the geared drive of the limit switch cams.
2. Adjust the appropriate cam so that the stop limit switch is just opening at this
hoist position (see procedure at the end of this chapter).
 RTG Maintenance Vol 2 – Special Procedures – Hoist Balance Adjustment 171

UPPER EMERGENCY-STOP LIMIT SWITCH (EACH HOIST)

Upper Emergency-Stop Limit Switch Operating Position 850 mm

(top of spreader pulley distance below level of gantry rails) (33.46 inch)

1. By using a temporary link wire between the terminals, by-pass the contact of
the emergency-stop limit switch.
Note!
This emergency-stop limit switch is directly connected into the control circuit
for the corresponding hoist inverter. It is not over-ridden when the crane is
selected to maintenance mode.
2. Using the local control push-buttons, carefully raise the hoist so that the
pulleys on the spreader head block are the correct distance below the hoist
drum for the operating position of this limit switch.
Note!
If the hoist is already above this height, it must be lowered to below the
switch operating position and then raised to the required level. This avoids
any back-lash errors in the geared drive of the limit switch cams.
3. Adjust the appropriate cam so that the emergency-stop limit switch is just
opening at this hoist position (see procedure at the end of this chapter).
4. Remove the temporary link wire from across the switch contact.
Do not forget this!

LIMIT SWITCH CAM ADJUSTMENT PROCEDURE

Fixing Screws for
Contact Block

Fine Adjustment
Screw

Hand-Wheel
on Cam Shaft

Each of the limit switches in the assembly is operated by its own individual cam
which is mounted on a common shaft.
The switching point of each limit switch can be adjusted by two different methods:
 RTG Maintenance Vol 2 – Special Procedures – Hoist Balance Adjustment 172

COARSE ADJUSTMENT (EACH LIMIT SWITCH CAM)

The switching position can be changed by re-aligning its cam on the common shaft.
1. Slacken the hand-wheel at the end of the cam shaft. This releases most of
the clamping force from a coil spring on the shaft.
2. Turn the individual cam on the shaft to re-align it at the correct switching
position. Take care not to turn the other cams!
3. Tighten the hand-wheel until it is hard against the shoulder on the shaft. This
compresses the coil spring and clamps the cams onto the shaft.

FINE ADJUSTMENT (EACH LIMIT SWITCH)

The fine adjustment of the switching point can be achieved by moving the individual
contact block on its mountings by a small amount.
1. Slacken the two fixing screws for the individual contact block.
2. Turn the separate adjustment screw to re-position the contact block on its
mountings, so that its switching point is changed as required.
3. Tighten the two fixing screws.
 RTG Maintenance Vol 2 – Special Procedures – Spreader Cable Change 173

E. SPREADER CABLE CHANGE

INTRODUCTION
The flexible cable between the spreader and the trolley is a special type of cable, with
several features that allow it to self-coil into the basket on the spreader. The cores
are made from fine strands of wire for good flexibility. The cable lay-up includes
several strings of lead beads which encourage the coiling and also reduce the effects
of side winds on the suspended cable.
Although the cable is specially designed for this application, the cable will wear out as
a result of continual crane operations. At the first sign that the outer sheath is
damaged or worn-through, the spreader cable must be replaced. The electric power
to the spreader hydraulic unit and the logic signals to and from the spreader are
essential for the continued operation of the crane.

NEW SPREADER CABLE PROCUREMENT

The specification of the replacement spreader cable must be the same as the original
one. The new cable should be procured directly from the manufacturer or via the
local distributor. Please refer to KONECRANES drawings for further technical details.
Note! There are several types of spreader cables with different sizes / numbers of
cores. Make sure that the correct cable is procured.
 RTG Maintenance Vol 2 – Special Procedures – Spreader Cable Change 174

SAFETY PRECAUTIONS BEFORE CABLE CHANGE

READ THIS FIRST

WARNING ! Read the following safety preacautions prior
starting changing the cable.

Gantry Parking Before changing the spreader cable, the gantry of the RTG crane
should be positioned at a suitable level location, away from any
container stacks.
Sufficient clear space must be available at ground level for laying
out the cable.
Trolley Traverse For the safe access, the trolley should be at the normal parking
Position position, where the main girders have additional hand-rails for
personnel protection.
Spreader Before the cable changing, the spreader must be retracted to
Hoisted to Max. minimum length and the hoists must be raised so that the
Height spreader is at maximum height.

Supply Before the cable changing is started, the electrical supply must be
Isolation ! isolated to the equipment on the trolley which includes the
spreader. The control supply must also be isolated.
While the cable changing is in progress, the gantry travel and
trolley traverse drives must also be prevented from being
operated.
All of these electrical supplies must be isolated (in the Electrical
Equipment Room).
 RTG Maintenance Vol 2 – Special Procedures – Spreader Cable Change 175

OLD SPREADER CABLE REMOVAL

Check Cable Check that the connection details at both ends of the old spreader
Connection cable are in accordance with the termination schedule (see Circuit
Details Diagrams, Volume 15). If not, record the differences so that the
new cable can be installed the same as the old one.

Cable After making sure that there is no voltage at the terminals,

Disconnection - disconnect the cores of the old spreader cable from the terminals
Trolley End on the trolley (in both cubicles). Cut off the ends of the old cable
cores, just inside the cable glands in the bottom of the cubicles.
Slacken the gland nuts and withdraw the bundles of cable cores
from their glands.
Cable End Attach a suitable synthetic rope onto the upper end of the old
Lowering into spreader cable.
Cable Basket The short vertical length of the spreader cable between the trolley
and the fully raised spreader is not too heavy to be supported by
hand (approximately 10 – 15 kg). If required, the rope can be
wrapped around a suitable fixed part of the structure to provide
additional security.
With the weight of the cable held by the rope, slacken the cable
clamp on the trolley and carefully lower the upper part of the old
cable into the basket on the spreader.
WARNING! Do not allow the old cable to drop down onto the ground from the
trolley.
This is dangerous to personnel. It is also likely to damage the
equipment.
The weight of a full vertical length of the spreader cable between
the trolley and the ground is 65 - 70 kg!
Spreader Temporarily, re-energize the control supply and the electrical
Lowering power supply to the hoists and to the auxiliary winches.
Using the joystick control in the Operator's Cab, lower the hoists
until the spreader is resting on suitable blocks of wood at ground
level.
 RTG Maintenance Vol 2 – Special Procedures – Spreader Cable Change 176

Supply Isolation Before continuing with the removal of the old spreader cable,
isolate all of the electrical supplies again.

Cable Disconnect the cores of the old spreader cable from inside the
Disconnection - terminal box on the head block of the spreader. Cut off the ends
Spreader Head of the old cable cores, just inside the cable gland in the bottom of
Block End the terminal box. Slacken the gland nut and withdraw the cable
from its gland in the terminal box.
Cable Removal Pull out all of the turns of the old cable that are resting inside the
from Basket on basket and allow the cable to fall onto the ground (by the side of
Head Block the spreader).

Disposal of Old Cut up the old cable into several shorter lengths, so that it cannot
Cable be used again by mistake. Discard these lengths of old cable into
a suitable waste disposal system.

INSTALLATION OF NEW SPREADER CABLE

CABLE DRUM POSITIONING

Each new SPREADERFLEX cable is supplied on a
drum.
Position the drum of new cable on the ground, next
to the side of the spreader.
Turn the supply drum onto its correct side, so that
the new cable is wound around it in the
anti-clockwise direction.
Note! The supply drum should not turn while its
cable is transferred into the basket on the spreader
head block (see later procedures).

CABLE FIXING - SPREADER HEAD BLOCK END

Un-coil the free end of the cable off from the top of
the drum and then feed it down through the neck
Neck
of the basket.
Feed this end of the cable through the aperture in
the bottom of the basket and then through
the sealing gland into the terminal box on the
spreader head block.
Make sure that there is a sufficient cable length
inside the terminal box. Then, tighten the gland so Cone
that it is sealed.
Re-fix the cable support clamps between the
basket and the terminal box. To
Terminal Box
 RTG Maintenance Vol 2 – Special Procedures – Spreader Cable Change 177

CABLE LUBRICATION
While the new spreader cable is being coiled into the basket, the cable should be
lubricated to ensure good self-coiling. The polyurethane outer sheath of the cable has
a high resistance to oil and grease. Various alternative lubricants can be used. An
important feature is that the lubricant must not wash off in the rain. A silicone type of
special lubricant for plastics and rubber can be sprayed onto the sheath.

CABLE COILING INTO BASKET ON SPREADER HEAD BLOCK

With the drum of new cable resting on its side,
un-coil the cable from the top side of the drum and
re-coil it inside the basket on the spreader head
block in an anti-clockwise direction.
Start by coiling around the base of the cone.
Coil cable
anti-clockwise
around cone

Important ! When the coils of cable are resting inside the basket, there must not be any
twisting load on the cable. Otherwise, the cable will not feed freely into and out
of the basket during normal crane operation.
If either the cable supply drum is the wrong way up, or the cable is coiled the
wrong way into the basket, there will be a twisting load on the cable.
Either of these errors must be corrected before the cable is transferred into the
basket

Then, continue coiling into the bottom of the basket

until the floor is covered.
Remember to lubricate the cable sheath!
Coil cable
anti-clockwise
until floor is
covered
 RTG Maintenance Vol 2 – Special Procedures – Spreader Cable Change 178

The remaining length of the cable should be coiled up

around the inside of the basket frame.
Remember to lubricate the cable sheath!
Providing that the diameter of the cable supply drum is
similar to that of the basket, no twists should develop Coil cable
anti-clockwise
in the cable as it is transferred from the side of the around inside
drum and into the basket. of basket

Transfer almost all of the new cable into the basket, so

that only a short length remains above the neck of the
basket.

CABLE END ATTACHMENT TO PULLING ROPE

Lower a suitable synthetic pulling rope from the trolley.
Attach this rope onto the free end of the spreader
cable.
A braided pulling "sock" can be used for this
attachment. Remember to make the temporary binding Braided Pulling "Sock"
around the bottom of the sock which ensures that the
cable is gripped properly.
Do not pull-up the new spreader cable to the trolley
until the spreader is fully raised. Otherwise, the
required twists will be released from the cable. Temporary Binding

Cable

SPREADER HOISTING TO MAXIMUM HEIGHT

Temporarily, re-energize the control supply and the electrical power supply to the
hoists and to the auxiliary winches.
Using the joystick control in the Operator's Cab, raise the hoists until the spreader is
at maximum height.
 RTG Maintenance Vol 2 – Special Procedures – Spreader Cable Change 179

CABLE INITIAL FIXING - TROLLEY END

Cable Raising Temporarily, re-energize the control supply and the electrical power
to Trolley supply to the hoists and to the auxiliary winches.
Using the joystick control in the Operator's Cab, lower the hoists
until the spreader is resting on suitable blocks of wood at ground
level.
Using the temporary pulling rope, raise the free end of the spreader
cable from the basket on the spreader and up to the trolley level.
Cable Clamp Position the new cable so that there is about 2 metres of free cable
above the clamp position.
Wrap a length of rubber sheet around the outside of the cable at the
clamp position. Then, tighten the clamp so that the cable is securely
anchored.
Note! Do not remove the pulling sock from the end of the cable at this
stage. It may be required during the correction of any cable
self-coiling problems (see later chapter).

CABLE SELF-COILING TEST

When the upper end of the new spreader cable has been clamped onto the trolley,
the self-coiling of the cable into the spreader basket must be tested.
Note! This testing must be done before the upper end of the cable is terminated.
Using the joystick control in the Operator's Cab, slowly lower the hoists until the
spreader is just above the ground level. During the spreader lowering, check that the
spreader cable feeds smoothly out of the basket.
Then, slowly raise the hoists until the spreader is at maximum height. During the
spreader raising, check that the spreader cable self-coils smoothly into the basket.
Providing that the self-coiling works without a problem at slow speed, repeat the
cycles of hoist lowering and raising, but at increasing speeds.
If the self-coiling works smoothly when hoisting at maximum speed, no correction is
needed and the installation can continue.
 RTG Maintenance Vol 2 – Special Procedures – Spreader Cable Change 180

CORRECTION OF CABLE SELF-COILING PROBLEM

If there is a self-coiling problem with the spreader cable, the appropriate correction
procedure must be carried out, depending on the problem.

Cable Does Not Self-Coil Into Spreader Basket

The vertical length of the suspended cable between the trolley
and the spreader should have a continuous twist over its full
height. This is essential if the cable is to self-coil into the basket.

If the cable is not twisted enough, the cable will not self-coil
correctly and will tend to fall over the outside of the spreader
basket. The cable can also form "figure-of-eight" loops inside
the basket.

To add additional twist into the spreader cable, carry out the following steps:
1. Position the spreader at maximum height.
2. While supporting the weight of the vertical length of the spreader cable using
the pulling rope, partially release the fixing clamp on the trolley.
3. Rotate the spreader cable inside the clamp by one complete turn in an
anti-clockwise direction (when viewed from above).
4. Re-tighten the clamp onto the cable.
5. Repeat the self-coiling test and make further corrections if necessary.

Cable Self-Coils Into Small Turns

The vertical length of the suspended cable between the trolley
and the spreader should have a continuous twist over its full
height.
If the cable is twisted too much, it can self-coil into small tight
turns inside only part of the basket. When the twist is correct,
most of the turns should self-coil at the full diameter of the
basket.
If the cable is twisted far too much, it can also form loops in the
vertical length of the suspended cable. These can "snag" in the
neck of the basket.

To remove excessive twist from the spreader cable, carry out the following steps:
1. Position the spreader just below maximum height.
2. While supporting the weight of the vertical length of the spreader cable using
the pulling rope, partially release the fixing clamp on the trolley.
3. Rotate the spreader cable inside the clamp by one complete turn in a
clockwise direction (when viewed from above).
4. Re-tighten the clamp onto the cable.
5. Repeat the self-coiling test and make further corrections if necessary.
 RTG Maintenance Vol 2 – Special Procedures – Spreader Cable Change 181

CABLE FINAL FIXING - TROLLEY END

Once the self-coiling of the new spreader cable has been tested, the remaining
installation stages for the new spreader cable can continue.
Spreader During the termination of the new cable at its lower end, the
Parking spreader must be resting on suitable blocks of wood at ground
level. In preparation for this, the spreader should be lowered to
the ground at the present stage of the installation.
Supply Isolation Before continuing with the electrical installation of the new
spreader cable, all of the electrical supplies must be isolated
again.

Pulling Rope There is no further requirement for the pulling rope and so it
Release / Sock should be released from the upper end of the new cable. The
Removal pulling sock should also be removed.

Cable Sheath Carefully cut back the polyurethane outer sheath of the cable to
the position just above the clamp.
Cable Attach bundles of the polyester reinforcement from the end of the
Reinforcement cable onto the two bolts above the clamp. This provides
additional support for the cable.
Sealing Glands Route the five bundles of cable cores through the correct sealing
glands in the bottom of the two trolley cubicles.
Make sure that there is a sufficient cable length inside each
cubicle. Then, tighten the glands so that they are sealed.

CABLE TERMINATIONS

Spreader Head First, the cores at the lower end of the cable should be terminated
Block End at the spreader head block in accordance with the termination
schedule (see the Circuit Diagrams in another volume)

Trolley End Before terminating this end, make sure that there is no voltage at
any of these terminals. Then, the cores at the upper end of the
cable should be terminated at the trolley cubicles in accordance
with the termination schedule (see Circuit Diagrams, Volume 15).
 RTG Maintenance Vol 2 – Special Procedures – Spreader Cable Change 182

FINAL VISUAL INSPECTION

Before the electrical power is re-energized at the completion of the installation, the
cable termination must be visually inspected at each end.
TROLLEY - Check that the cable clamp is tight.
END - Check that the sealing glands are tight.
- Check that all of the cable cores are terminated into the correct
terminal blocks.
SPREADER - Check that the sealing gland is tight.
HEAD BLOCK - Check that all of the cable cores are terminated into the correct
END terminal blocks.

FUNCTIONAL TESTING
Before the crane is made available for normal use, the functions of the cable cores
must be tested (using the controls / indications in the Operator's Cab).

Motor Direction Re-energize the electrical supplies and then start the hydraulic
of Rotation unit on the spreader. Check that the motor / pump rotates in the
correct direction.
Flippers With the spreader suspended clear of the ground, check that
Operation each pair of flippers raises and lowers correctly.
Spreader With the spreader suspended clear of the ground, check that the
Telescopic Drive telescopic drive operates correctly and that the spreader can be
Operation set at all three alternative lengths.
Spreader Feeler Lower the spreader onto the top of a container and check that the
Pins "Spreader Landed" status indication changes state.
Spreader With the spreader resting on the top of a container, check that the
Twist-Locks twist locks operate correctly and that status indication changes
state.
 RTG Maintenance Vol 2 – Special Procedures – Bogie Jackings 183

F. BOGIE JACKINGS
INTRODUCTION

READ THIS FIRST

WARNING ! Prior jacking the bogie the safety information at
the beginning of this manual must be observed.

Each gantry travel bogie can be jacked-up easily for changing the wheels or for other
maintenance activities. This ‘Bogie Jacking’ instruction is divided in two parts:
First part is describes the jacking procedure for one wheel pair, which is useful when
changing a flat tire, for example.
The second part shows the rarely needed procedure for jacking up the whole bogie,
which is useful when bearings in king pin are changed, for example.

SAFETY PRECAUTIONS - BEFORE JACKING

READ THIS FIRST

WARNING ! Follow the instructions below prior jacking the
bogie.

Parking on The gantry of the RTG crane must be parked on a level site.
Level Site If not, there is a danger of the bogie falling off the jack.
If necessary, the crane should be moved slowly to an area of
level ground, even if one of the rubber tyres is flat or has a
puncture.
Wheel Chocks The wooden chocks must be placed under both sides of the two
wheels of the other bogie (at the same corner of the gantry).
Isolation of The electrical supplies to all of the gantry travel drives must be
Gantry Travel isolated to ensure that the crane cannot move.
Supplies
No High Winds If there are high winds, a bogie should not be supported only by a
jack. During very large gusts, the sideways forces on the gantry
may cause the jack to topple and the bogie to fall to the ground.
 RTG Maintenance Vol 2 – Special Procedures – Bogie Jackings 184

IF MOTOR NEEDS TO BE REMOVED, ISOLATE THE FOLLOWING GANTRY

TRAVEL SUPPLIES:
Motor Cooling The two common electrical supplies to the cooling fans for all of
Fans the gantry travel motors must be isolated to ensure that each fan
can be dismantled safely. (The cooling fans for four gantry travel
motors are fed from each supply)
Mechanical The common electrical supply to the mechanical brake release
Brake Release circuits for all of the gantry travel drives must be isolated to
ensure that the brake mechanism can be dismantled safely.
Anti- The common electrical supply to the anti-condensation heaters
Condensation for all of the gantry travel motors and brakes must be isolated to
Heaters ensure that each motor or brake can be dismantled safely.

WARNING ! The electrical supply can be alive even when the

diesel-alternator is shut down.
It can be fed from the auxiliary power cable (via
the change-over switch).

SAFETY PRECAUTIONS - DURING ADVERSE

CONDITIONS
There could be some circumstances where jacking is necessary during adverse
conditions, where the crane is not on level ground or there is a high wind.
For example, a wheel might have been damaged and need changing before the
crane can be moved.

READ THIS FIRST

WARNING ! Follow the instructions below prior jacking the
bogie.

Alternative In these circumstances, additional safety precautions must be

Lifting taken, to ensure that the jack cannot topple while lifting the bogie.
Arrangements It may be preferable to use an alternative lifting arrangement,
other than a hydraulic jack.
Single Wheel As an additional safety precaution during adverse conditions, only
Removal one wheel should be removed from the crane at any one time.
 RTG Maintenance Vol 2 – Special Procedures – Bogie Jackings 185

PREPARATIONS BEFORE JACKING

Gantry Travel To permit easy access to all of the gantry travel wheels, all of the
Mode bogies should be aligned in the normal "long travel" direction.
If necessary, change the gantry travel mode to this long travel
direction.
Trolley at So that the best weight distribution is obtained between the gantry
Parking bogies, the trolley should be at its normal parking position
Position (opposite end from the diesel-alternator).
If necessary, the trolley should be traversed to the parking end of
the main girders.
Spreader Load The crane should not be supporting any un-necessary load while
Supporting a gantry wheel is removed.
The spreader should be lowered so that it is resting on the
ground, supported by suitable blocks of wood.

WHEEL CHANGE (FLAT TIRE)

INTRODUCTION
The procedures in this section apply to changing just a single gantry wheel that has a
flat tire or where the wheel rim or tire is damaged.
Read the safety information carefully before starting the work (at the beginning of this
section.)
If more than just one wheel needs to be changed (or both wheels on a single bogie),
refer to the following section "Jacking the Whole Bogie".

BOGIE JACKING DETAILS

JACKING LOCATION
Pivot (behind terminal box)
The casing of each gantry travel gearbox is
fabricated from structural steel. It is
designed to accept the forces from a jack
placed below the central axis of the gearbox.
There is a special jacking pad for additional
reinforcement on the bottom of the casing. Jackin
Heigh
The recommended minimum lifting capacity 60 mm

of the hydraulic jack is 25 tonnes. This is

sufficient to lift the bogie safely during all
conditions, even if the crane is supporting a
fully laden container. Wooden Chocks under Both Wheels 25-Tonne Hydraulic Jack
 RTG Maintenance Vol 2 – Special Procedures – Bogie Jackings 186

MINIMUM JACKING HEIGHT

To raise a bogie sufficiently so that either of
the wheels can be removed, the hydraulic
jack must be capable of lifting the gearbox
by a height of about 60 mm.
BASE PLATE
To distribute the ground loading and to
provide a stable base, it is recommended
that a steel plate should be positioned on
the ground, underneath the hydraulic jack.
A suitable plate of width 550 mm can be
fitted in between the tyres at ground level.
The thickness of this plate may be limited by
the minimum height of the retracted jack. A
plate of thickness 60 mm can be used with a
typical 25-tonne hydraulic jack. 60

60 550
PACKING PLATES
Since the base width of most hydraulic jacks is small so that they can be fitted in
restricted spaces, it is preferable that their height should be kept to a minimum.
Additional packing plates should be used to take-up any large clearance. Wide
packing plates on the top of the base plate provide a more stable lifting arrangement
than a hydraulic jack which is extended more than necessary.

WHEEL PAIR JACKING PROCEDURE

Fit Wheel Before the wheel pair is jacked up, the wooden wheel chocks
Chocks must be fitted under both sides of the two wheels of the other
bogie at the opposite end of the balancing beam.

Wheel
Chocks

WARNING ! The mechanical brake only operates on one of the

two wheels for each bogie. The other wheel is free
to turn.
Initial Jacking Fit the jack under the bogie in the correct position. Then, operate
the jack until it supports most of the bogie weight. At this time, do
not raise the bogie until the tyres are clear of the ground.
Slackening of Only half of the gantry wheels are held stationary by the
 RTG Maintenance Vol 2 – Special Procedures – Bogie Jackings 187

Wheel Nuts mechanical brakes, as shown in the following diagram:

Free Brake Brake Free

Brake Free Free Brake

Trolley

Cab

Brake Free Free Brake

Free Brake Brake Free

A "free" wheel must be prevented from rotating while its wheel

nuts are slackened. This is achieved by having the tyre in contact
with the ground during the slackening procedure.
For each gantry wheel, there are 12 wheel nuts which attach the
wheel to the hub studs. The tightening torque for each wheel nut
should be released by turning it for about a ¼ turn in an anti-
clockwise direction. This should be done in the same order as
used for the tightening sequence (see the diagram in a later
chapter of this section).
CAUTION! Until the wheel is jacked-up clear of the ground, do
not completely slacken the wheel nuts.
Bogie Final Once the tightening torque has been released from the
Jacking appropriate wheel nuts, the jack should be raised until the tyre is
just clear of the ground.

WHEEL REMOVAL
Wheel Weight The appxomate weight of the wheel is 240 kg (530 lb).
Supporting
Before the wheel nuts are removed, the weight of the wheel must
be supported by an approved lifting device. A fork-lift truck or a
pallet truck would be suitable for this application.
WARNING ! The weight of the wheel is far too heavy to be lifted
or supported by human hand.
Wheel Nuts Once the weight if the wheel is suitably supported, the twelve
Removal wheel nuts should be removed.
Wheel Removal The wheel should be withdrawn horizontally from the hub by
from Hub moving the fork-lift truck (or pallet truck), taking care not damage
the threads on the hub studs.
 RTG Maintenance Vol 2 – Special Procedures – Bogie Jackings 188

PUNCTURE REPAIR / TYRE CHANGE

The puncture repair or tyre change requires special tools and equipment.
It is recommended that the old wheel should be sent to a tyre specialist, either for a
puncture repair or for a tyre change.
The specialist is best able to advise when a puncture cannot be repaired and hence
when a new tyre must be fitted.

WHEEL RE-FITTING
Wheel Fitting The re-fitting of the wheel onto the hub is the reverse of the
onto Hub removal procedure.
Firstly, the wheel should be positioned so that the holes in its
flange are aligned with the studs on the wheel hub.
Then, the wheel should be located onto the hub by moving the
fork-lift truck (or pallet truck), taking care not damage the threads
on the hub studs.
Wheel Nuts Before the wheel nuts are re-fitted onto the studs, their threads
Fitting should be lightly coated with a suitable copper based, anti-seize
compound.
Then, all of the wheel nuts should be threaded onto their studs
until the spherical face of each nut is fully engaged into its mating
recess in the wheel flange.
Jack Partial Before the wheel nuts can be tightened, the jack must be lowered
Lowering until the tyre is in contact with the ground. At this time, do not
lower the jack until the wheels of this bogie are supporting their
full load.

TABLE - TIRE PRESSURE

Product Pressure
Nokian 14.00-24 28PR L-3 9.5 bar (138 PSI)
Good Year 14.00-24 28PR HRL-3 10 bar (145 PSI)
 RTG Maintenance Vol 2 – Special Procedures – Bogie Jackings 189

WHEEL NUTS TIGHTENING

80% Tightening Torque 100% Tightening Torque
400 N-m (295 lb-ft) 500 N-m (369 lb-ft)
1
12 5 The wheel nuts should be tightened to the
correct torque in two stages, using a suitably
calibrated torque wrench.
8 9
Firstly, the wheel nuts should all be tightened
to 80% of the full torque, in the sequence
4 3 shown below.
Secondly, the wheel nuts should all be
tightened to the full 100% torque in the same
10 7
sequence.
6 11
2

Wheel Nut Tightening Sequence

JACK REMOVAL
Jack Final Once the wheel nuts have been fully tightened, the jack should be
Lowering lowered carefully, until the tyres are supporting the full load of the
bogie.
Jack Withdrawal When the jacking is not required any longer, the jack should be
withdrawn from beneath the bogie and any additional supporting
plates should be removed.
Chocks Finally, the wooden chocks should be removed from beneath the
Removal other bogie wheels and returned to their stowage locations.
 RTG Maintenance Vol 2 – Special Procedures – Bogie Jackings 190

JACKING THE WHOLE BOGIE

INTRODUCTION
At each corner of the gantry, the two bogies are mounted on a balancing beam with a
central pivot onto the gantry frame. If it is necessary to dismantle a bogie for overhaul
maintenance work (such as changing the kingpin bearings), the gantry corner load
must be supported below the centre of the corresponding balancing beam.
The fitting of a suitable support structure under one corner of the gantry is slightly
more complicated than just jacking-up the two bogies and lowering the balancing
beam back onto this structure.
Read the safety information carefully before starting the work (at the beginning of this
section.)

Jacking
Height
100mm

Wooden Chocks under Motor + Brake removed

all other Gantry Wheels from Outer Bogie

MOTOR + BRAKE REMOVAL - OUTER BOGIE

Before the temporary support structure can be
installed between the two bogies, the motor
and brake assembly must be removed from
the outer bogie.
It should be possible to move the complete
motor and brake assembly from its normal
position, without disconnecting the flexible
cables from their terminals.
Disconnection The flexible cables need to be released from their mountings to
of Cable provide sufficient slack for the removal of the motor.
Mounting Near to the steering joint, the cables are held by brackets with
Brackets multiple clamps. Rather than slackening the clamps, these
brackets should be released from the balancing beam. This
ensures that each flexible cable will be positioned correctly when
the bogie is re-assembled.
Removal of The complete assembly of the motor, the mechanical brake and
Motor + Brake the cooling fan can be removed as a single unit.
Assembly
 RTG Maintenance Vol 2 – Special Procedures – Bogie Jackings 191

While supporting the weight of this assembly (~140 kg), remove

the four M16 bolts between the motor flange and the gearbox.
Withdraw the motor axially, until the drive coupling is released
from the spline of either the motor shaft or the gearbox shaft.
Stowage of During the other maintenance work, this motor and brake
Motor + Brake assembly can be suspended below the bogie balancing beam by
Assembly a suitable lashing.

JACKING PROCEDURE
1. Jack-up both bogies by about 100 mm.
(see separate procedure – Bogie Jacking)

Note:
2. Position the temporary support structure Terminal Box
below the centre of the bogie balancing extends below
beam. Balancing Beam
Note that the terminal box extends below
the bottom face of the balancing beam
which prevents the use of a larger trestle.

3. Carefully lower each jack until the

balancing beam is resting on the top of the
temporary support structure.
500

Temporary Support
under Bogie Balancing Beam

4. Remove the wheels from the bogie that

requires the maintenance work.

5. Release the jack from below the bogie that

requires the maintenance work.

It is recommended that the wheels and the

jack should not be removed from the other
bogie at the same time.
 RTG Maintenance Vol 2 – Special Procedures – Bogie Jackings 192

GEARBOX / KING PIN LOWERING DETAILS

1. Using a pallet trolley (or fork-lift truck) to
support the weight of the gearbox and
kingpin (~1000 kg), release the bolts from
the flange between the bogie balancing
beam and the kingpin bearings.
2. Lower the pallet trolley (or fork-lift truck) so "Pallet"
that the kingpin bearings are withdrawn Trolley
from the bottom of the vertical tube.
 RTG Maintenance Vol 2 – Special Procedures – Trolley Jacking 193

G. TROLLEY WHEELS / BEARINGS

CHANGING
READ THIS FIRST
WARNING ! Prior starting the trolley wheels / bearings changing
the safety information at the beginning of this
manual must be observed.

INTRODUCTION
Each trolley carriage can be jacked-up easily for changing the trolley wheels or for
changing the hub bearings.
Two special brackets are required for this jacking. These are bolted onto either end of
the carriage.
When a carriage has been jacked-up, suitable temporary supports can be inserted
between the carriage structure and the rail. Then, the carriage can be lowered onto
these supports and the jacks can be removed. This gives better access to the trolley
wheels during the overhaul maintenance work.
The recommended minimum lifting capacity for each jack is 5 tonnes. This assumes
that there is no load suspended from the trolley, i.e. the spreader is resting on the
ground (or on the top of a container).
 RTG Maintenance Vol 2 – Special Procedures – Trolley Jacking 194

SAFETY PRECAUTIONS - BEFORE JACKING THE

TROLLEY

READ THIS FIRST

WARNING ! Follow the instructions below prior jacking the
trolley.

Gantry Parking The gantry of the RTG crane must be parked on a level site. If
on Level Site not, there is a danger of the trolley falling off the jacks.
Spreader The spreader must be resting on the ground (or on the top of a
Resting on container). The hoist ropes and auxiliary ropes must be
Ground with sufficiently slack to permit the trolley to be jacked-up by at least
Slack Ropes 100 mm, without tensioning the ropes.
Isolation of The electrical supplies to all of the crane drives must be isolated
Supplies to All to ensure that the crane cannot move while this overhaul
Crane Drives maintenance work is in progress.
Wheel Chocks Suitable chocks must be placed under both sides of the two
wheels of the other trolley carriage.

WARNING ! Borth trolley carriages must not be jacked-up at the

same time.

The wheel flanges ensure that the trolley is located correctly on the top of the gantry.

TROLLEY JACKING
Temporary
TEMPORARY BRACKETS (AT Bracket
EACH END OF CARRIAGE)
Remove the buffer by undoing the four
attachment bolts.
Fit the temporary bracket using the four 4 Bolts
M12 x 40
M12 bolts (tightening torque 65 N-m).
65 N-m
 RTG Maintenance Vol 2 – Special Procedures – Trolley Jacking 195

HARDWOOD "SADDLE" (AT

EACH END OF CARRIAGE)
To protect the rail from local damage and
to provide a stable base for the jack, it is
recommended that a hardwood "saddle"
should be fitted over the rail. This should
rest on both the top of the rail and on the
top of the main girder.
Hardwood "Saddle"

RETRACTED JACK LENGTH

With a hardwood saddle height of 90 mm,
the distance between the temporary
bracket and the saddle is about 430 mm.

5-Tonne
CARRIAGE LIFTING Jack
With a suitable jacks at the ends of the
carriage, operate both jacks at the same
time to raise this side of the trolley.
Warning! Do not jack-up only
one corner of the
trolley at a time.
MINIMUM JACKING HEIGHT
To raise a trolley sufficiently so that the
temporary supports can be fitted between
the carriage and the rails, each jack must
be capable of lifting the carriage by a
height of 100 mm.
Cable
TEMPORARY SUPPORTS Power-Track
Position the two temporary supports
Temporary
between the trolley carriage and the rail. Support
Then, carefully lower both jacks at the
same time, until the carriage is resting on 51
the supports.
If the height of these supports is 124 mm,
the trolley wheels will be 90 mm above the
rail.
Note: There is only a clearance of 51 mm
between the power-track for the cables
and the carriage.
 RTG Maintenance Vol 2 – Special Procedures – Position Measurements 197

H. LOAD CONTROL AND POS.

MEASUREMENTS
LOAD MEASUREMENT AND CALCULATION

LOAD MEASUREMENT EQUIPMENT

The tensile loads are measured continuously for all hoist ropes at corners of the
trolley. For each measurement, there is a load cell with integrated amplifier in the
attachment coupling at the fixed end of the rope. The signal from the load cell is fed
to an analogue input of the remote PLC in the Trolley cubicle.
The load in each auxiliary winch is calculated automatically in PLC by converting the
torque and speed feed back in corresponding drive to load values.

LOAD CALCULATIONS
In the PLC the measured tensile load on the hoist ropes is used for various load
calculations.

Hoist Load
For each hoist the loads on its two hoist ropes are assumed to be the same.
The calculated Hoist Load takes into account that the hoist ropes are doubled
around pulleys on the spreader head block and return back up to the trolley.
Hence, the Hoist Load is four times the measured load for one of its hoist ropes.
Each calculated Hoist Load also includes the loads of the appropriate auxiliary
ropes, again taking into account that these ropes are doubled around pulleys on
the spreader head block.
For ease of interpretation, each Hoist Load value is converted from a unit of
force into a unit of mass.

Total Load
The Total Load is the sum of the two Hoists Loads and calculated load from
Auxiliary Winches while they are in use.

Spreader Load
The correct value for the spreader self weight is preset in the PLC during the
initial commissioning by KONECRANES. This preset value is subtracted from
the Total Load to give the calculated Spreader Load.
When there is some load on the spreader, the following logic functions apply :
1. Bogie Pivoting, Gantry Cross Travelling and Turning are not allowed.
2. Limit Hoist Raising or Lowering Speed as a function of Spreader Load
(at up to 50%... Full Speed).
 RTG Maintenance Vol 2 – Special Procedures – Position Measurements 198

No Load
When there is no load on the spreader, the following logic functions apply :
1. Permit Gantry Cross Travelling at up to 60% Full Speed.
2. Permit Gantry Turning at up to 60% Full Speed.
3. Permit Gantry Long Travelling at up to Full Speed.
4. Permit Trolley Traversing at up to Full Speed.
5. Permit Hoist Raising or Lowering at up to Full Speed.

AUXILIARY WINCHES
During the normal operation of the crane, each auxiliary winch is continuously
adjusted to keep its rope load within the normal working range.
Since this control is fully automatic, there are no Operator actions associated with the
auxiliary winches.

LOAD INDICATION DISPLAYS

The calculated value of the Spreader Load is always available on the main page of
the PLC Information Display.
Note: The value of the "Spreader Load" on the main page of the Operator's display
does not include the self weight of the spreader and its head block.
The individual values of the hoist rope loads are also available on one of the
maintenance pages of the PLC Information Display.
The individual values of the auxiliary rope loads are available at one of the PLC
maintenance pages.

SLACK ROPE DETECTION

The calculated Total Load is used in the PLC for the slack rope detection system.
The status of the slack rope detection is used to protect the crane against unsafe
operations. The hoist drives and the other motions are either inhibited or their speed
is limited, depending on the status of the slack rope detection.
Note: The slack rope logic only applies to the control commands from the
Operator's Cab and does not affect the local control push buttons during
maintenance work.

ROPES SLACK
When the calculated Total Load is below the "slack rope" level, the following logic
functions apply :
1. Inhibit Hoist Lowering.
2. Limit Hoist Raising to Slow Speed.
3. Limit Gantry Travelling to Slow Speed.
4. Limit Trolley Traversing to Slow Speed.
 RTG Maintenance Vol 2 – Special Procedures – Position Measurements 199

ROPES TIGHT (NOT SLACK)

When the calculated Total Load is above the "slack rope" level, the following logic
functions apply :
1. Permit Hoist Raising and Lowering at up to Full Speed (see also Spreader
Load).
2. Permit Gantry Travelling at up to Full Speed (see also Spreader Load).
3. Permit Trolley Traversing at up to Full Speed (see also Spreader Load).

OVERLOAD PROTECTION
The load of the container is not necessarily equally distributed between the four hoist
ropes or between the two hoist drums.
In the design of the crane, the combined load capacity of the two hoists is greater
than the total load capacity of the crane. Similarly, the combined load capacity of the
two ropes on each hoist drum is greater than the load capacity of each hoist.
The overload protection system is taking into account the possibilities of an
asymmetrical container load. This is achieved by having two different overload
warning and stop systems :
1. Crane Overload.
2. Hoist Overload for each of the two Hoists.

CRANE OVERLOAD WARNING

When the calculated Total Load is above the overload warning level, the "Crane
Overload Warning" alarm message is raised on the PLC Information Display.

WARNING ! While the Overload alarm is active, continued

raising of the hoist or any movements of the trolley
or the gantry must only be carried out slowly and
with great care.

When the Overload Warning alarm is active, the problem should be cleared by
carefully lowering the load back onto the ground or onto any other suitable resting
place.

NOTE: The overload can be caused by any of the following reasons :

1. The container contents are over- weight.
2. The container is attached to something else.
(e.g. the transport truck or the next container in the stack).
3. The spreader or the container is "snagged" on a fixed obstruction.

HOIST OVERLOAD WARNING

When the measured Rope Load on either of the monitored ropes is above the
overload warning level, the "Hoist Overload Warning" alarm message is raised on the
PLC Information Display.
The actions and notes are the same as for the Crane Overload Warning alarm.
 RTG Maintenance Vol 2 – Special Procedures – Position Measurements 200

CRANE OVERLOAD STOP

When the calculated Total Load is above the overload stop level, the "Crane
Overload Stop" alarm message is raised on the PLC Information Display.
The following logic functions also apply :
1. Gantry Travelling, Trolley traversing and Hoist raising are not allowed.
2. Limit Hoist Lowering to Slow Speed (both hoist drives).

When the Overload Stop alarm is active, the problem must be cleared by carefully
lowering the load back onto the ground or onto any other suitable resting place.

HOIST OVERLOAD STOP

When the measured Rope Load on either of the monitored ropes is above the
overload stop level, the "Hoist Overload Stop" alarm message is raised on the PLC
Information Display.
The logic functions and the actions are the same as for the Crane Overload Stop.

AUXILIARY ROPE OVERLOAD STOP FUNCTIONS

If the calculated load on any one of the four auxiliary ropes exceeds the overload
stop level, the "Auxiliary Rope Overload Stop" alarm message is raised on the PLC
Information Display.
The following logic functions also apply :
1. Hoist Raising is not allowed.
2. Inhibit All Auxiliary Winch Movements (Spreader Fine Position and Slew).
Because the auxiliary winch control is automatic, this overload stop level can only be
reached if one of the auxiliary winches is not operating correctly.
When this alarm is active, the load should be carefully lowered back onto the ground
or onto any other suitable resting place, so that the problem can be investigated.
This problem cannot be rectified by the Operator and hence the specialist help from
the Maintenance Personnel is required.
WARNING ! While Maintenance Personnel are investigating
and rectifying the fault care must be taken to
avoid an accident.

Caution ! If the spreader is raised while the auxiliary winches are not working,
the auxiliary rope loads can increase.
From the auxiliary rope geometry, each auxiliary winch is normally
required to slowly slacken (feed out) its rope as the hoist is raised.

If the auxiliary winch problem cannot be rectified, there is a special maintenance

procedure to slacken the four auxiliary ropes and to disable the auxiliary winches
(see Special Procdures section in this manual).
The limited operation of the crane is then permitted until the auxiliary winch system
can be repaired. However, the normal sway suppression system and the spreader
fine positioning controls will not be available during this time.
See the ‘Direct Motor Control’ paragraph in the ‘Special Procedures’ section.
 RTG Maintenance Vol 2 – Special Procedures – Position Measurements 201

LOAD CELLS CALIBRATION

Hoist load cells are factory adjusted and further calibrations are not required.
There are no load cells in the auxiliary winches. The load in auxiliary winches is
calculated automatically in PLC by converting the torque and speed feed back in
corresponding drive to load values.

HOIST SPEED SUPERVISION

SPEED SUPERVISION AND POSITION EQUIPMENT

Each hoist and auxiliary winch motor has an incremental pulse encoder unit on the
outboard end of the motor shaft (in hoist motor hidden by the fan assembly).
Each pulse signal is fed to the motor control equipment and then transferred to
master PLC for monitoring.

Speed Supervision Equipment (NOVA)

The analogue value of the measured speed is compared with the inverter output
frequency in a hoist motion overspeed supervision unit.
Because this system continuously monitors the speed error for each hoist drive,
any loss of control which results in an overspeed will be detected. This
detection method will operate much sooner than a conventional fixed value
overspeed switch, especially if the speed demand level is low.
Each supervision unit also has a ‘Stall Supervision’ function.
Further information about NOVA is presented in separate DYNAC /
DYNAHOIST Owner’s Manual (at the end of this folder).

HOIST SPEED FAULT

If the speed supervision equipment detects a fault condition, the hoist drive is shut
down by its associated control equipment.
On such a fault, the mechanical brake on the hoist drive is applied without any delay.
A fault signal is also sent to the PLC.
When any fault signal is received from the control equipment of either hoist drive, the
PLC carries out the following control actions for both of the hoist drives:
1. Clears the "mechanical brake release" signal.
2. Sets the reference speed demand to zero.
3. Clears the raise / lower direction control output signals.
This ensures that the other hoist drive is also stopped and its mechanical brake
applied by a fault on one hoist drive.
The corresponding "Hoist Equipment Fault" message also flashes onto the alarm
page of the PLC Information Display and the audible alarm is sounded in the
Operator's Cab.
After a control equipment fault signal from either hoist drive, the PLC logic software
prevents the further raising or lowering of the hoist for a period of 3 seconds. This
timer is to discourage any attempt to ignore the fault.
 RTG Maintenance Vol 2 – Special Procedures – Position Measurements 202

The speed supervisory equipment will reset automatically, a few seconds after the
hoist has stopped.
The PLC will also reset automatically, providing that :
1. The equipment fault condition has cleared.
2. The brakes are engaged on both hoist drives.
3. The hoist joystick is in the centre position.
If an equipment fault has been detected in either hoist drive the problem cannot be
rectified by the Operator. A specialist help from the Maintenance Personnel must be
requested.

WARNING ! While Maintenance Personnel are investigating and

rectifying the fault care must be taken to avoid an
accident.
Do NOT attempt to operate the hoist until the
problem has been investigated by the Maintenance
Personnel.
Do NOT release the mechanical brakes on either
hoist drive unless the head block / spreader (and its
load) are resting on the ground or they are fully
supported by other means.

"WINCH SPEED ERROR" FUNCTIONS

In case PLC detects too low or high auxiliary winch speed, the hoist motion is
stopped and fault of appropriate winch is raised on PLC display panel.

HOIST POSITION CALIBRATION

The hoist position calibration can be done by the operator. Please refer to Operator’s
Manual for further instructions.
Additionally, more detailed information for trouble shooting purposes can be found
later in this manual in ‘Hoist Position Calibration’ paragraph in section ‘PLC for
Maintenance’.

TROLLEY POSITION CALIBRATION

One trolley traverse motor has an incremental pulse encoder unit on the outboard
end of the motor shaft.
The trolley position is automatically checked by proximity switches mounted on one
side of the trolley. These switches are also used for checking the slow-down and stop
functions of the trolley traverse motion (by the PLC). For these functions there are
detecting plates on the main girder and arranged so that different combinations of
proximity switches are activated at different regions of the trolley traverse motion.
The trolley position calibration can be done by the operator. Please refer to
Operator’s Manual for further instructions.
 RTG Maintenance Vol 2 – Special Procedures – Direct Motor Control 203

I. DIRECT MOTOR CONTROL

It is possible to operate each motor using the front panel controls of its DYNAHOIST
or DYNAC inverter. However, this is not recommended (except in an emergency)
because the limit switches, the overload protection and the other interlock features
are by-passed (these are provided via the PLC logic).
If it is necessary to drive each machinery from its inverter, the external stop hardware
circuit and the front panel features are similar to those of the DYNAC inverters for the
auxiliary winches.

TEMPORARY CONNECTION OF BRAKING RESISTORS -

IMPORTANT!
The same braking resistors are used for the hoist inverters and for the gantry travel
inverters. To directly operate either hoist from the front panel of its inverter, the
correct resistors must be temporarily connected to the inverters.
Before the braking resistors are connected to the hoist inverters, they must be
prevented from being connected to the gantry travel inverters at the same time. For
this, the control contactor R-K50 must be temporarily disabled by disconnecting its
energizing signal from the PLC output (see the electrical drawings).
To connect the braking resistors to the hoist inverters, the control contactor A-K50
must be energized with a temporary link wire (see the electrical drawings).

MACHINERY OBSERVER(S)
Because each hoist, trolley traverse or bogie inverter is inside the Electrical
Equipment Room, a direct view to the hoist, trolley traverse or bogie machinery is not
possible while operating the front panel controls.

WARNING ! Do not directly operate the inverter without at least

one separate observer watching the machinery.
Observe also the spreader and load when operating
the hoist inverter.
To avoid an accident or other machinery damage,
the observer can always use any Crane Emergency
Stop push-button to trip the electrical supplies to the
inverters.
 RTG Maintenance Vol 2 – Special Procedures – Local Hoist Control 205

J. LOCAL HOIST CONTROL

On the trolley, there is local control for the two hoist drives. This is useful during
maintenance work on the hoist ropes or when checking the operation of the hoist
machinery.

1. SELECT THE CONTROL PLACE TO THE LOCAL

PUSH- BUTTONS

When this local control is required:

- Connect the plug on the outside
socket at the other end of the trolley
cubicle.
- The insertion of this plug into its
mating socket automatically
disables the hoist controls in the
Operator's Cab.
- Before either hoist drive can be
operated using this local control, the
crane must also be selected to
"Maintenance Mode" by turning the
key switch in the PLC cubicle either
on trolley or in the electrical
equipment room.
 RTG Maintenance Vol 2 – Special Procedures – Local Hoist Control 206

2. USE THE LOCAL PUSH- BUTTONS

Either hoist drive can be chosen for
local operation by using the selector
switch in the end of the local hand
control.

Each direction control push- button has

a 2- stage operation for "Very Slow
Speed" and "Slow Speed". The
selected drive only operates while
either button is pressed.

Direction control push-button for trolley

has only one speed. Trolley is moved
A1 A2
to the selected direction only while
button is pressed.

WARNING ! While the crane is selected to Maintenance Mode,

the slow-down and stop limit switches for the hoist
drives are by-passed in the PLC.
Other safety interlocks such as the overload
protection are also by-passed.

3. SELECT THE CONTROL PLACE BACK TO THE OPERATOR'S

CAB
When this local control is not required for further operation:
- Disconnect the plug off the socket
- The local control and it’s wandering lead should then be stowed inside
the cubicle (on the trolley).
- Before the crane can be operated from the controls in the Operator's
Cab, the key switch (in the Electrical Equipment Room or trolley) must
also be selected back to "Normal Mode".
 RTG Maintenance Vol 2 – Special Procedures – Solving Steering Problems 207

K. SOLVING STEERING PROBLEMS

When the gantry travel mode is changed, it is possible but unlikely for a steering
problem to occur with one of the bogies.
In most cases, the Operator can cure the problem by using the Bogie Turning Re-
start feature by pressing the function key F7 (see Volume 1 - User's Manual).
However, there might be some other problems that cannot be overcome by the
Operator.

CORRECTING THE BOGIE STEERING ANGLE

If the absolute position encoder for the bogie steering angle does not function
correctly, it is possible for the control system to become "lost" while changing the
steering angle. If this happens, the control system can drive the bogie steering angle
to beyond its normal working range.
On each bogie, a separate stop limit switch is activated when the steering angle goes
beyond the end of its working range. The limit switch stops any further motion of the
bogie drive motor and engages its mechanical brake, additionally mechanical stops
are provided also. In this way, the flexible cables to the bogie are protected against
any damage from being pulled too tight by a steering problem.
Note! Once this stop limit has activated, no further driving of the gantry can be done
from the Operator's Cab. The problem must be remedied by the maintenance
personnel by using the Bogie Single Mode function.
If the absolute position encoder (or its PLC interface module) has been
repaired / replaced or if its transmission gears have been disconnected for any
reason, the encoder position must be re-calibrated at the preset steering
angle, before the steering direction can be changed by the control system.
 RTG Maintenance Vol 2 – Special Procedures – Solving Steering Problems 208

BEFORE OPERATING ‘SINGLE MODE’

R L Before a bogie is driven individually from the

R4
L R R6 cab (or from the front panel of its inverter),
the bogie must be visually inspected for any
R3 R5
L R mechanical damage or loose / missing
R L fixings, including the transmission gears for
the absolute position encoder.
Then, the required running direction must
be established. This is complicated by the
fact that the inner wheel is driven for the
bogies at each corner of the gantry, but the
Trolley outer wheel is driven for the other bogies.
This is best explained by reference to the
diagram below:
Cab The eight driven wheels are identified by the
reference to their gantry travel inverter drive,
as shown in the electrical drawings.
L R
The "L” (Left) and "R" (Right) bogie turning
R R1 R7 L directions correspond with the turning
R2 R8 directions of the joystick in the cabin.
R L
L R

Once the bogie has been inspected and the steering direction has been determined, the
appropriate gantry travel drive can be operated from the cab in "Single Bogie" mode.
Single mode is turned ON automatically by the control system when a bogie operation fault
occurs. There is no switch or any other control means for the operator / service technician
to activate the single mode ON.
In PLC select the Single Mode screen 21 and operate as explained on the screen.
For further information check the ‘Bogie Single Mode Operational Screen - Screen 21’
paragraph in section ‘PLC for Maintenance’.

JAMMED STEERING LOCK

The changing of the steering direction between different turning modes assumes that
the pin in each steering lock can be withdrawn by its mechanism.
Although unlikely, it is possible that a locking pin may become jammed in its hole so
that it cannot be withdrawn by the steering lock mechanism. This might occur if the
RTG crane was being operated over rough ground and a bogie was stopped in a
position where there was a high torsional force being resisted by the locking pin.
To overcome this problem, the individual bogie drive can be operated to turn the
steering by a small amount and hence release the jammed steering lock pin.

BEFORE RELEASING THE STEERING LOCK

The locking pin must be closely examined to establish which direction the bogie must
be turned. This may be difficult because there is very little clearance space to view
the pin where it enters its locating hole.
 RTG Maintenance Vol 2 – Special Procedures – Solving Steering Problems 209

The bogie drive can then be operated from the cab in "Single Bogie" mode.
Note!
If the correct steering direction cannot be determined by visual inspection, the bogie
drive may need to be operated for a short duration in each direction until the locking
pin can be released.
If the steering lock cannot be released in single bogie mode from the operator's cab,
instructions for the direct operation of a bogie are provided in other chapter of this
manual. It is important to operate the inverter to correct direction.
Caution !
Only operate the bogie drive for a short duration.
Do NOT jam the steering lock in the other direction!

RELEASING THE STEERING LOCK

The steering lock of the bogie may also need to be released as part of the
emergency operation. This can be done by manually operating the appropriate
direction control contactor for the steering lock motor using a suitable insulated tool.
This must only be carried out by personnel with the necessary technical expertise.
The eight steering lock motors S1 ... S8 correspond with the bogie drives R1 ... R8.
The control contactors for the "release" (unlock) direction of each steering lock motor
are identified as S1-K2 ... S8-K2 respectively (see the electrical drawings).
Caution !
The end of travel limit switches for the steering lock are by- passed when the control
contactors are not commanded from the PLC.
Only operate the contactor to energize the steering lock motor for a short duration
and do NOT leave it energized after the lock mechanism has reached its end
position.
If the steering lock needs to be engaged again as part of the emergency operation,
this can also be done by operating the control contactor for the appropriate steering
lock motor (providing that the steering angle is aligned with one of the three locking
positions). The control contactors for the "engage" (lock) direction are identified as
S1-K1 ... S8-K1 respectively (see the electrical drawings).

MACHINERY OBSERVER
Because each gantry travel inverter is inside the Electrical Equipment Room, a direct
view of the bogie machinery is not possible while operating the front panel controls.
WARNING ! Do not directly operate any gantry travel inverter
without a separate observer watching the machinery.

Note!
To avoid an accident or other machinery damage, the observer can always use any
Crane Emergency Stop push-button to trip the electrical supplies to the inverters.
 RTG Maintenance Vol 2 – Special Procedures – Solving Steering Problems 210

Once the locking pin has been released, the correct operation of the locking
mechanism must be checked. This can be done by changing the steering direction
using the selector switch in the Operator's Cab (after the inverters for bogie drives
have been selected back to receive their commands from the PLC).
 RTG Maintenance Vol 2 – PLC and Display Panel 211

L. PLC AND DISPLAY PANEL

PLC DISPLAY PANEL (OP270)

The PLC Display Panel provides an easy to use display of the measurements and
operating parameters used by the PLC control system. The panel provides a list of
any fault alarms and warning messages that have been received by the PLC from its
monitoring of the control equipment. The panel also provides some facilities to reset
the automatic control systems after a fault has been cleared.
The display panel is a proprietary component from the same manufacturer as the
Master PLC. However, the display pages are configured by KONECRANES to
provide the appropriate information for the operation and maintenance of the crane.
The touch keys on the front panel are used to select the appropriate page on the
display. The keys are also used for entering the User's identification number before
starting the crane and for logging off when finishing (or at the end of a shift).
 RTG Maintenance Vol 2 – PLC and Display Panel 212

KEYS ON THE PLC DISPLAY PANEL

Numeric Keypad
The numeric key pad is at the top right of the panel.
This is used for entering your Identity Number when logging
into the PLC and for page selection.

After keying in the required sequence of numeric keys, the

number is entered into the PLC by pressing the "ENTER" key
(at the bottom right of the panel).
If a mistake is made while keying in a number, the "ESC" key
can be pressed to cancel all of the number and start again.
This cancel key should be used if the mistake is made in a
password, because the number sequence is only displayed
as asterisks (****) so that the password remains secret.
This cancel key also clears the Help-texts on the screen after
iHelp-button is pressed.
Alternatively, to delete just the last keyed character in a
number, the "DEL" key can be used.
If the "A-Z" key is pressed so that either of its LEDs is
illuminated, the keypad changes its function to alphabetic
entry mode (i.e. letters A...Z).
Check this button.

Check this button.

Navigation Keys
The navigation keys can be used to move up and down a list,
e.g. a list of alarms or events.
The navigation keys can also be used to move the cursor left
or right when entering numbers or text.

Scroll back. Scroll one page back.

Scroll forward. Scroll one page forward.

 RTG Maintenance Vol 2 – PLC and Display Panel 213

Acknowledge Key
The "ACK" key is used to acknowledge / accept alarm
messages.
The indicator LED illuminates when there is one (or
more) unacknowledged alarm in the alarm list.
For more details, see later chapter.

Function Keys F1...F8

F1 F2

F3 F4

F5 F6

F7 F8

The F1...F8 keys at either side of the display screen are pre-programmed to do
different functions irrespective of which page is selected.
By pressing the iHelp button on the main screen a window showing the available
functions, if any, is opened.
Each of these keys also has a small indicating LED in the top left corner. This LED
illuminates to show that the function is selected (i.e. when its key has been pressed
once). This LED goes out to show that the function is cancelled / not selected
(i.e. when its key has been pressed for a second time).
 RTG Maintenance Vol 2 – PLC and Display Panel 214

Function Keys F9...F14

F9 F10 F11 F12 F13 F14

The F9...F14 keys immediately below the display screen are programmed to do
different functions, depending on which particular display page is shown.
Each of these keys has a small indicating LED in the top left corner. This LED
illuminates to show that the functions are selected (i.e. when its key has been
pressed once). This LED goes out to show that the function is cancelled / not
selected (i.e. when its key has been pressed for a second time).
When these keys are used for a specific function, an appropriate label is shown on
the displayed page, immediately above each key.

Function Keys K1...K10

K1 K2

K3 K4 K5 K6 K7 K8 K9 K10

The K1...K10 keys below the display screen can be programmed to do specific
functions, independent of which particular display page is shown.
Each of these keys also has a small indicating LED in the top left corner. This LED
illuminates to show that the function is selected (i.e. when its key has been pressed
once). This LED goes out to show that the function is cancelled / not selected
(i.e. when its key has been pressed for a second time).
Note that there are no legends on the displayed pages for these function keys, so
the user must refer to the appropriate section of the manuals to obtain details of
their function.
 RTG Maintenance Vol 2 – PLC and Display Panel 215

LOG IN TO PLC
After the RTG is powered up and the OP-panel completed booting up, the screen will
instruct to enter the user ID number (password).

1. Press for “Passwords” with F9 and give correct password. LOGIN-window will then
appear.
2. Type the correct password using the numeric keypad on the upper right corner of the
panel (the screen display an asterisk for every digit i.e. ****). Press ENTER-key at the
lower right corner of the panel.
3. If your password is approved by OP-panel, the log in level number is shown on right of
[Link] one (1) is for Operators and level three (3) for maintenance people. If
password is incorrect, the message window “Password incorrect” is shown. Clear
window by “ESC’ –key and re-enter correct password.
4. Press F13- under the screen display key (MAIN) to start the controls and change to
MAIN-screen.
− The maintenance mode log in allows to access and operate all operator's level
(i.e. normal mode) OP-panel screens 1 thru 9, control switches and crane
operations as explained above. Additionally the maintenance mode allows
access to all other screens and to operate maintenance functions of the OP-
panels in the cab and the E-room.
 RTG Maintenance Vol 2 – PLC and Display Panel 216

INFORMATION DISPLAY – MAIN SCREEN

At the top of the main screen, there are two lines which are reserved for messages
from the PLC (Message Line). These messages are for information and should not
be confused with the alarm system (see later in this document for the alarm display
description).

During the normal operation of the RTG crane, the main screen is displayed (as
illustrated above). This screen shows the current values of the most important
operating parameters that are calculated in the PLC. Each of these parameters is
described below.

1. Current load of container, shown in metric tons.

2. Current hoist position is shown in meters.
3. Current hoist trim value in angles.
4. Reference value for hoist trim if trim memory position K3 or K4 is used.
5. Current trolley position in meters
6. Spreader fine position directions.
7. Left clearance against collision.
8. Right clearance against collision.
9. OP panel Date & Time
Note! Setting up date and time is described in greater detail in the appropriate
instruction section of Maintenance Manual, section PLC Displays, Setting
OP. Panel Password.
 RTG Maintenance Vol 2 – PLC and Display Panel 217

At the bottom of this screen, there are labels above the appropriate function keys
which give access to other features. The basic functions available to an operator are:

Screen Function Action

Label Key
Trolley F9 When this function key is pressed, the trolley position value
Position is reset to 0.0 on the main screen. This key only resets the
value on the main screen.
This procedure shall not be used for resetting the
trolley position faults.
LOGOUT F13 When this function key is pressed, the present user is
logged out from the PLC system (providing that the Drives
Supply is OFF).
All further control actions and PLC display selections are
then disabled until a new identification number is entered
by an authorised user and it is accepted by the PLC.
Screen F14 When this function key is pressed, the display changes to
Selection show the list of available screens for selection by the
logged-in user.

SCREEN SELECTION*
At the bottom of this screen, there are labels above the appropriate function keys
what give access to other features. These functions are:
 RTG Maintenance Vol 2 – PLC and Display Panel 218

Screen Function Action

Label Key
More F9 When this function key is pressed, the display changes to
screens show the next list of available screens.
Note! This function is only available for users with access
level 3 and above.
MAIN F10 When this function key is pressed, the display changes to
show the Main information display screen.
Go to F11 Before this function key is pressed, the user must first
SCREEN enter the desired screen number following the Enter key by
using the numeric keypad at the right of the panel.
When this function key is pressed, the display changes to
show the chosen screen (providing that the user has a high
enough access level for permission to view the chosen
screen).
Note! If the access level of the user is not high enough, the
text ‘Screen not available’ is shown on the screen. Clear
this message window by pushing the ESC-button.

ALARM WINDOW

ALARM OCCURRENCE
When a new alarm occurs, the audible warning is sounded (beep once) and the
alarm window appears over the top of the current display screen, as shown in the
sketch above.
Each alarm message has three lines of information and a typical message would look
as follows:
 RTG Maintenance Vol 2 – PLC and Display Panel 219

The first line has the reference number of the alarm message, the status letter (see
later description of alarm messages) and the time and date that the alarm occurred.
The second and third lines contain abbreviated text which describes the initiating fault
condition for the alarm.
The number on the right of the window shows how may alarms have not been
acknowledged (accepted).

ALARM ACKNOWLEDGEMENT (ACCEPTANCE)

ACK
To acknowledge (accept) an alarm message, press the
"ACK" (acknowledge) key on the display panel.
This clears the alarm window if no other alarms are waiting to
be displayed.
When all alarms are acknowledged, the LED in the key will go
off.

ACTIVE ALARM REMINDER SYMBOL

While any alarm remains active because its initiating fault
condition has not cleared a blinking "Active Alarm Reminder
Symbol" is displayed in the corner of the screen.
This symbol automatically clears from the screen when there
are no active alarms.

Change Window Key

At any time, the user can change the window shown on the
display by pressing the "K1" or “K2” keys. Each press of “K1”
key steps to the Active Events window.
Each press of “K2” key steps to the Active Alarms window.
 RTG Maintenance Vol 2 – PLC and Display Panel 220

EVENT PAGES - "K1" FUNCTION KEY

K1
The Event pages can be selected by pressing the "K1"
function key at any time, providing that a user is logged in
(access level 1 or higher). Login is not required for this
function in the e-room panel (optional).
The indicator LED in the "K1" function key is illuminated to
confirm when the Event pages can be selected.

ACTIVE EVENTS PAGE

When the "K1" function key is pressed once, the Active Events page is displayed.
The Active Events page gives a list of current events, with the most recent event at
the top of the list.
Each Event message has three lines of information. The first line starts with the
reference number of the event message and the status letter "I" for "initiated". This is
followed by the time and date that the event occurred. The second and third lines
contain abbreviated text which describes the initiating condition for the event.
When the cancelling condition for an event occurs, the message is automatically
deleted from the Active Events page.

The Active Events page only allows a limited number of event

messages to be viewed at any one time.
If the number of active events exceeds the display size, the
"up" and "down" cursor keys can be used to scroll through the
list.
“HOME” button jumps to first event in the Active Events list.
“END” button jumps to the last event.
 RTG Maintenance Vol 2 – PLC and Display Panel 221

Events Log Page

K1
By pressing the "K1" function key for a second time, the
display changes from the Active Events page to the Event
Log page.
The Event Log page gives a historical record of all events that have occurred, with
the most recent event messages at the top of the list.
For each event message, there is an entry in the log when the event is "initiated" and
a second entry when the event is "cancelled". These can be distinguished by the
status letters "I" and "C" in the first line of each message.
Note that the status of the initiating event message also changes from "I" to "IC"
when the cancelling event occurs. In this way, only the active events have just the
single status letter "I" in the Event Log.

The Event Log page only allows a few event messages to be

viewed at any one time.
By using the "up" and "down" cursor keys, the event list can
be scrolled to view the earlier event messages.
After the Event Log page becomes full (512 messages), the earliest message is
discarded when a new event message occurs.

RETURN TO PREVIOUS SCREEN FROM EVENT PAGES

ESC
To return to the previous screen after viewing the Active
Events page or the Event Log page, the "ESC" key must be
pressed.
 RTG Maintenance Vol 2 – PLC and Display Panel 222

ALARM PAGES - "K2" FUNCTION KEY

K2
The Alarm pages can be selected by pressing the "K2"
function key at any time, providing that a user is logged in
(access level 1 or higher). Login is not required for this
function in the e-room panel (optional).
The indicator LED in the "K2" function key is illuminated to
confirm when the Alarm pages can be selected.
Active Alarms Page

When the "K2" function key is pressed once, the Active Alarms page is displayed.
The Active Alarms page gives a list of current alarms, with the most recent alarm at
the top of the list.
Each Alarm message has three lines of information. The first line starts with the
reference number of the message and the status letter(s) "I" for "initiated" and "A" for
"acknowledged (accepted)". This is followed by the time and date that the event
occurred. The second and third lines contain abbreviated text which describes the
initiating condition for the alarm.
When the initiating condition for an alarm clears, the message is automatically
deleted from the Active Alarms page.

The Active Alarms page only allows a limited number of alarm

messages to be viewed at any one time.
If the number of active alarms exceeds the display size, the
"up" and "down" cursor keys can be used to scroll through the
list.
 RTG Maintenance Vol 2 – PLC and Display Panel 223

“HOME” button jumps to first event in the Active Alarms list.

“END” button jumps to the last alarm.

ALARM LOG PAGE

K2
By pressing the "K2" function key for a second time, the
display changes from the Active Alarms page to the Alarm
Log page.

The Alarm Log page gives a historical record of all alarms that have occurred, with
the most recent alarm messages at the top of the list.
For each alarm message, there is an entry in the log when the alarm is "initiated", a
second entry when the alarm is " acknowledged (accepted)" and a third entry when
the alarm is "Cleared". These can be distinguished by the status letters "I" , "A" and
"C" in the first line of each message:
I =Alarm Initiated
A =Alarm Acknowledged (Accepted)
C = Alarm Cleared
Note that the status of the initiating alarm message also changes from "I" to "IA"
when the alarm is acknowledged (accepted), and from "IA" to "ICA" when the alarm
is cleared. In this way, only the un-acknowledged, active alarms have just the single
status letter "I" in the Alarm Log.

The Alarm Log page only allows a few alarm messages to be

viewed at any one time.
By using the "up" and "down" cursor keys, the alarm list can
be scrolled to view the earlier alarm messages.
After the Alarm Log page becomes full (512 messages), the earliest message is
discarded when a new alarm message occurs.
 RTG Maintenance Vol 2 – PLC and Display Panel 224

RETURN TO PREVIOUS SCREEN FROM ALARM PAGES

ESC
To return to the Previous screen after viewing the Active
Alarms page or the Alarm Log page, the "ESC" key must be
pressed.

HELP WINDOW (ADDITIONAL INFORMATION)

For some of the alarm messages and event messages, additional information text is
available to assist the Operator or maintenance person.

The indicator LED in the "i HELP" key illuminates when such
HELP
additional information is available for the selected message.
By pressing the "i HELP" key, the additional text is displayed
in a "Help" window which appears over part of the existing
display screen.

Note! This additional information can only be accessed while either the Event
Log page or the Alarm Log page is being displayed.

RETURN TO EVENT / ALARM PAGES FROM HELP WINDOW

ESC
When the additional information has been read, the "Help"
window is cleared from above the message buffer screen by
pressing the "ESC" key.
 RTG Maintenance Vol 2 – PLC and Display Panel 225

GUIDE TO MAINTENANCE LEVEL

FUNCTIONS
Following are the instructions for selected PLC maintenance level (level 3) functions.
Notice that all the screens described here in may not be included in your cranes.
These screens depending the selected options with cranes.
Following are description how the buttons are used to control screen selections and
other functions on screen:

Note! Function keys may vary depending options delivered with the cranes.
Notice always text or figure of button before pressed.
These function keys are not described later in this manual.

Screen Function Action

Label Key
Previous F9 When this function key is pressed, the display changes to
Screen show the previous available page.
Next F10 When this function key is pressed, the display changes to
Screen show the next available page.
F11 When this function key is pressed and it is available on
current page, the selected page is sent to printer. Printer
has to be connected in order to perform this function.
Available only in the Electrical room panel.
Note! Function key F11 may vary on different page!
MAIN F13 When this function key is pressed, the display changes to
show the Main information display screen.
Note! Function key F13 may vary on different page!
Screen F14 When this function key is pressed, the display changes to
selection show the first screen selection page.
Note! Function key F14 has two different functions
depending on what page is selected!
 RTG Maintenance Vol 2 – PLC and Display Panel 226

LISTS OF MAINTENANCE DISPLAY SCREENS

All of the maintenance display screens can be accessed from the lists of available
screens.

Following function keys are used to select desired screen.

Screen Function Action

Label Key
Go To F14 Before this function key is pressed, the user must first
Screen enter the desired screen number following the Enter key by
using the numeric keypad at the right of the panel.
When this function key is pressed, the display changes to
show the chosen screen (providing that the user has a high
enough access level for permission to view the chosen
screen).
Note! If the access level of the user is not high enough, the
text ‘Screen not available’ is shown on the screen. Clear
this message window by pushing the ESC-button.
 RTG Maintenance Vol 2 – PLC and Display Panel 227

LIST (1-9) OF AVAILABLE SCREENS - SCREEN 190

LIST (10-19) OF AVAILABLE SCREENS - SCREEN 191

LIST (20-29) OF AVAILABLE SCREENS - SCREEN 192

 RTG Maintenance Vol 2 – PLC and Display Panel 228

LIST (30-39) OF AVAILABLE SCREENS - SCREEN 193

LIST (40-49) OF AVAILABLE SCREENS - SCREEN 194

LIST (50-59) OF AVAILABLE SCREENS - SCREEN 195

 RTG Maintenance Vol 2 – PLC and Display Panel 229

LIST (60-69) OF AVAILABLE SCREENS - SCREEN 196

LIST (70-79) OF AVAILABLE SCREENS - SCREEN 197 (VER 1)

LIST (70-79) OF AVAILABLE SCREENS - SCREEN 197(VER 2)

 RTG Maintenance Vol 2 – PLC and Display Panel 230

LIST (80-89) OF AVAILABLE SCREENS - SCREEN 198

LIST (90-99) OF AVAILABLE SCREENS - SCREEN 199

LIST (100-109) OF AVAILABLE SCREENS - SCREEN 200

 RTG Maintenance Vol 2 – PLC and Display Panel 231

(OPTIONAL)

LIST (110-119) OF AVAILABLE SCREENS - SCREEN 201

LIST (120-129) OF AVAILABLE SCREENS - SCREEN 202

 RTG Maintenance Vol 2 – PLC and Display Panel 232

LIST (120-129) OF AVAILABLE SCREENS - SCREEN 202

LIST OF ALARMS AND EVENTS - SCREEN

 RTG Maintenance Vol 2 – PLC and Display Panel 233

LIGHTS CONTROL SCREEN - SCREEN 4 (OPTIONAL)

This page is shown only if this function is included in crane (optional).
At the bottom of this screen, there are labels above the appropriate function keys
what give access to other features. These functions are:

Screen Function Action

Label Key
Walkway F9 When this function key is pressed, walkway lights are
lights turned ON or OFF depending of the last state of the lights.
Truck lane F10 Same as above, but for truck lane lights.
Trolley F11 Same as above, but for trolley lights.
lights
Gantry F12 Same as above, but for gantry lights.
lights
 RTG Maintenance Vol 2 – PLC and Display Panel 234

ANTI – COLL. SENSITIVITY REDUCTION - SCREEN 18

(OPTIONAL)
This screen shows the control parameters for the ultrasonic anti - collision detectors
that are applicable when the sensitivity reduction is selected by the operator (by
pressing the F4 function key). Led on function key F4 is blinking as long as selection
is active. To cancel selection, press F4 again while gantry is not running.

It is possible for the maintenance personnel to select the appropriate level of

sensitivity reduction, based on experience of the most extreme weather (heavy rain)
conditions that occur at the site.
If the ultrasonic anti-collision protection gives nuisance activation in bad weather,
even when the sensitivity reduction mode is selected, the parameters can be
changed to the next preset level. Each higher level of sensitivity reduction gives
increased time delays before activation, but also reduces the maximum speed limit
for the gantry travel.

SETTING THE REDUCTION LEVEL

Cursor is on previously selected reduction level. To change value of reduction, press
Enter. Select new value by arrows up ▲ or down ▼ and press Enter.

WARNING ! The more that the anti – collision sensitivity is

reduced, the greater is the risk of collision
damage or an accident when approaching a
real obstruction or a person on the site
runway.
 RTG Maintenance Vol 2 – PLC and Display Panel 235

OPERATOR’S SETTINGS - SCREEN 108,109

This screen shows the some of the crane control parameters that Operator can
select.

After the selected this screen, the cursor is on first selection. Move the cursor on
desired function by arrow-keys, up ▲ or down ▼.
By pressing the Enter-key option window is shown of available choices. Select
desired function by arrows up ▲ or down ▼ and press Enter. Window is closed and
current selection is shown on screen.

Function Available Action

choices
Auto TW ON / OFF This function is used to disable or enabled automatic
locks twistlocks. If automatic twistlocks are selected ON, the
twistlocks are automatically locked when landed on
container.
Note! Automatic unlocking is always disabled.
Trim A Automatic / This function either enabled or disabled automatic trim
mode Manual function on the truck lane area.
Trim B Automatic / Same as above, but to be used on stack area.
mode Manual
 RTG Maintenance Vol 2 – PLC and Display Panel 236

SOFTWARE STOP AND SLOWDOWN - SCREEN 13

This screen is used for hoist and trolley software stops and slowdown, set by
operator. This function can be used for example if digging the last container on same
stack lane to easier trolley operations to find same stack lane.

1. Shows current trolley lane (follows trolley position)

2. Selected stack’s stopping lane. To activate trolley to stop on this lane, use
function key K5. LED on key is illuminated while activation is on.
Select trolley to stop on truck lane by pressing function key K7.
Select another stack lane by pressing function key K6 as many times than
desired lane shown.
3. Actual stopping point for each lane on stack and also truck lane.
-To fine tune desired stop point, move trolley to that point and press function
key K8. Value is stored to position.
-Repeat above step for each lane separately.
4. Measured trolley position in metres.
5. Actual stopping point for hoist when trolley is on truck lane. Activate this stop limit
by function key K9. To set new stop position for hoist, move spreader desired
height and press function key K10.
6. Measured hoist position in metres.
7. Maximum hoist speed in m/s (metres/second)
 RTG Maintenance Vol 2 – PLC and Display Panel 237

COUNTER / HOUR SCREENS

Any (maintenance) person who is logged into the PLC with access level 3 or higher
can view additional PLC display pages that are not available to an operator.

CONTAINER COUNT - SCREEN 5

Ver 1
For each size of container, two values are displayed. The first value is the total
number of containers during the whole life of the crane. The second value is the
sub-total since the container count was last reset.

Ver 2

For all size of container, two values are displayed. The first value is the total number
of containers during the whole life of the crane. The second value is the sub-total
since the container count was last reset.
 RTG Maintenance Vol 2 – PLC and Display Panel 238

CONTAINER COUNT RESET

Screen Function Action

Label Key
Reset F12 When this function key is pressed, the container count
values values are reset to zero.

Pressing the "F12" function key causes all of the "Since Reset" sub-totals to be reset
to zero and the "Reset Date" is changed to the current date.
Note! If the "F12" function key is pressed, there is no going back to the previous
values!
Note! The total count values for the whole life of the crane cannot be reset from
the PLC Display Panel.
For each size, the container is assumed to be "empty" if its weight is less than the
corresponding value in the following table:

Container Size "Empty" Weight Value

20 ft 5250 kg
40 ft 8100 kg
45 ft 9000 kg
 RTG Maintenance Vol 2 – PLC and Display Panel 239

MACHINERY HOURS - SCREEN 6

A separate count is kept of the running hours for the RTG and for each of the
principal motions. The timing condition for each running hours counter is shown
below:

Running Hours Counter Timing Condition

RTG Drives Supply ON

Hoists Hoist Mechanical Brakes Released
Gantry Travel Gantry Travel Mechanical Brakes Released
Trolley Traverse Trolley Traverse Mechanical Brakes Released
Auxiliary Winches Auxiliary Winches Mechanical Brakes Released

Note! These values are reset in case Simatic S7-software is downloaded or lost
PLC backup battery. To save these values for further use, upload DB7
from PLC before new software is downloaded and download it back after
PLC start up.
 RTG Maintenance Vol 2 – PLC and Display Panel 240

ROUTINE MAINTENANCE HOURS - SCREEN 7

HOUR COUNT RESET

Screen Function Action

Label Key
Reset F12 When this function key is pressed, the hour count values
overflows are reset to zero.
This function can be used, if any of the counter values
have become so large that they cannot be displayed
correctly on this screen.

Note! These values are reset in case Simatic S7-CPU is changed.

 RTG Maintenance Vol 2 – PLC and Display Panel 241

MESSAGE PROCESSING - SCREEN 19

Via this screen (shown only at maintenance level) can panel messages can be either
deleted from buffers and/or sent to printer.
Date and time settings can be changed and download method selected. See
instructions below.

TIME AND DATE SETTINGS

1. Cursor on this selection, date can be set using numeric keypad.
2. Cursor on this selection (move by arrow keys), time can be set using
numeric keypad.

DOWNLOADING THE OP. PANEL

To download the project from the configuration computer to the operating unit, the
following steps must be taken care of:
1a. Connect the OP panel and Field PG (Siemens laptop) using the
connecting cable between COM1 –port (in laptop, IOIO –mark) and
Config/Printer –port bottom of the panel. (see the equipment manual).
This is serial download.
OR
1b. Connect the OP panel and Field PG (Siemens laptop) using the
connecting cable between Profibus DP–port (in laptop, MPI/DP –mark)
and selected point on profibus network. It can be one of the places
where 9-pin profibus-DP subconnector is available. This is MPI
Download.

2a. Set the operating unit to the transfer mode. Turn off power supply by
removing power supply plug behind the panel. Connect power back and
press and hold key combination ESC + cursor →. Release them
reverse order when text “Trans. Mode” –show on screen.
OR
 RTG Maintenance Vol 2 – PLC and Display Panel 242

2b. On screen 19 select download and push Enter. Select ‘MPI Download’
or ‘Serial’ (depending on which cable and mode is selected to use) and
press Enter. Panel turn automatically to download mode.
You will find more information on the transfer mode in the equipment manual.
3. Open ‘Protool’ –program. Open project file (e. g.
C:\G319_Maersk_CabinOP for Cabin Operator’s panel).
4. Start the downloading of the configuration by choosing the File →
Download → Start … menu command.
If having connection problems, check communication setting by choosing
File → Download → Preferences … menu command.
For serial download, select serial download and select COM1 and 56000
baud rate.
For MPI download select MPI/Profibus DP and select correct address.
5. Start the downloading of the configuration by choosing the File →
Download → Start … menu command.
6. After establishing connection to OP-panel save the project on FLASH.
After the download has been completed, the operating unit starts up and
displays the start screen.
 RTG Maintenance Vol 2 – PLC and Display Panel 243

INFORMATION DISPLAY SCREENS

The maintenance screens in the range 20...30 show the values of various measured
input parameters, used by the PLC for the control of the RTG crane.
Each screen is self - explanatory and shows a group of similar parameters.
Following screens can be used crane operational information monitoring. These
screens help during fault finding.

SPEED REFERENCES– SCREEN 23

On this screen are shown inverter feedback, PLC reference and joystick feedback
values. Values are in percentages.

GANTRY SPEEDS – SCREEN 100

On this screen are shown inverter feedback, PLC reference and joystick feedback
values. Values are in percentages.
 RTG Maintenance Vol 2 – PLC and Display Panel 244

ACM TORQUE FEEDBACK – SCREEN 28

This page shows torque feedback from inverters and PLC software reference to
inverters.

HOIST/TROLLEY POSITION ENCODERS – SCREEN 29

This screen shows position feedback from hoist and trolley encoders. Values are in
meters. Also braking resistor current is shown in amperes.
 RTG Maintenance Vol 2 – PLC and Display Panel 245

BOGIE POSITION ENCODERS – SCREEN 22

This screen shows position feedback from all bogie position encoders. Values are in
hex-decimal and degrees.

BOGIE LOADS – SCREEN 26

This screen shows average load on each gantry machinery.

 RTG Maintenance Vol 2 – PLC and Display Panel 246

WEIGHING – SCREEN 27

This screen shows each measured load cell value on main hoist and calculated load
value of each ACM inverters. Total load with and with out spreader are shown lower
right corner in kilo Newtons and metric tons.

DRIVE STATUS SCREENS – SCREENS 31 TO 48

The maintenance screens in the ranges 31...37 and 41...48 show the important
status information for each inverter drive, used by the PLC for the control of the RTG
crane.
Most of these control values and status signals are transmitted as data parameters
between each inverter and the Master PLC via the PROFIBUS.
Each screen is self - explanatory and shows the relevant information for a single
inverter.
The following illustration is a typical example and shows the status display
for the inverter of Hoist A1 (screen 31):
 RTG Maintenance Vol 2 – PLC and Display Panel 247

LC STATUS AND I/O DISPLAY SCREENS

The maintenance screens in the ranges 50 … 79 shows the status information for the
PLC system, including all of the digital inputs and outputs.
Each screen is self - explanatory and shows the relevant information for a particular
function. Where more than one screen is needed to display all of this information,
there are quick links to the next or previous screens by using the function keys.
The following illustration is a typical example and shows one of the PLC I/O display
screens for the Hoist A1 Inputs (screen 55):

These inputs are grouped into the locations of the remote I/O racks that are near to
the particular hoist equipment. For example, the protection circuit breaker for the
mechanical brake release is located on the trolley; the NOVA module for the hoist
speed protection is located in the electrical room.
Note! The fail - safe inputs are energized (on) when the protection equipment is
in the normal / healthy condition and go off in the
trip / fault condition.
 RTG Maintenance Vol 2 – PLC and Display Panel 248

INVERTER FAULT LOGS – SCREENS 82 TO 98

The three most recent faults are stored in the memory of each inverter drive and are
displayed on the appropriate status information display screen.
However, the last twenty faults for each inverter drive are also recorded in the PLC.
These longer fault logs for each inverter are shown on the maintenance display
screens in the ranges 82...88 and 91...98.

Typical inverter fault log screen.

 RTG Maintenance Vol 2 – PLC and Display Panel 249

BYPASS AND SETTING SCREENS

Some of the maintenance screens allow operational functions to be commanded from
the PLC display panel by pressing the appropriate function keys.

LOAD CELL BYPASS – SCREEN 80

This screen shown in the E-room screen (optional) only. Operate load cell bypass by
following steps.

1. Select faulty load cell pressing and hold correct number and press function key
F11. Measured load cell value (1) is copied to bypass value from nearest load cell
(2).
2. Reset bypass pressing function key F12.
Note! Three load cells can be bypassed at the same time.
 RTG Maintenance Vol 2 – PLC and Display Panel 250

OVERLOAD BYPASS – SCREEN 81

WARNING ! This function is used only for annual testing of

the crane or after hoist rope change.
Do not use for normal operations!

This screen shown in the E-room screen (optional) only. Operate bypass by following
step. All operation speeds of the crane are lowered during bypass.

Bypass overload pressing the function key F11. Timer starts running for 10 minutes.
After time the overload bypass is turned off. Restart timer by pressing F11 again if
necessary.
Turn bypass off by pressing function F12.
Note! Overload bypass is limited to 135% of crane rated load!
 RTG Maintenance Vol 2 – PLC and Display Panel 251

HOIST POSITION CALIBRATION – SCREEN 24

This screen is shown in the E-room (optional) and Cabin screens. Operate hoist
position setting by following step.
Operate the hoist to the up stop limit. Trim spreader to a level. Press F12-key to set
both hoists to same value. Hoist height is possible to set if one of the upper stop limit
switches is activated.
This function is used by maintenance level only.

TROLLEY LIMIT SWITCH CALIBRATION – SCREEN 107

This screen is shown in the E-room (optional) and Cabin screens. Operate trolley
position calibration by following step.

Drive trolley forward to end of main girder (diesel side) to stop limits. Drive trolley
back to gate. PLC measures new values for each switch when they are recognised.
Push function keys F9 to F12 while trolley is stopped to store new values in the PLC.
 RTG Maintenance Vol 2 – PLC and Display Panel 252

CRANE OPERATIONAL SETTINGS –SCREEN 75

This screen is used to modify some crane operational settings. Crane user can edit
these functions according to the yard surface etc.
Use following instructions to change settings.

After the selected this screen, the cursor is on first selection. Move the cursor on
desired function by arrow-keys, up ▲ or down ▼.
By pressing the Enter-key option window is shown of available choices. Select
desired function by arrows up ▲ or down ▼ and press Enter. Window is closed and
current selection is shown on screen.

Function Available Action

choices
Gantry turn 10 This function is used to change bogie turning speed.
speed different Depending on container yard surface (asphalt vs.
speed concrete) bogie may turn too fast and give over travel
selection faults.
Hint! Lower speed is normally used on concrete
surfaces.
Wheel turn Inner This function allows to control bogie wheel turn sequence
mode wheels in two steps or all the bogies at the same time.
first/All at Two step control keeps crane steady during wheel turning
the same sequence.
time
Turn start Wait until This setting either wait all the locking pins to be unlocked
mode all up/No position prior to start bogie turn or each individual bogia
waiting start turning as soon as locking pin is unlocked position.
 RTG Maintenance Vol 2 – PLC and Display Panel 253

OPERATIONAL DISPLAY SCREENS

ACM SPEED MODE CONTROL – SCREEN 25

Operating drives is possible in the cab only. E-room screen (optional) is only for
viewing.
Note! Maintenance mode shall be activated to use this function.

Operate ACM drives on the speed mode control as explained below.

1. Select/reset Auxiliary Winch Machinery by pressing and holding numeric keypad
and press function key F11.
2. OR select all machinery by pressing function key F12.
3. Control selected machinery to loosen or tighten by trolley joystick (forward trolley
loosen the rope and vice versa).
4. Reset all machinery by pressing function key F13.
Note! Trolley driving is not possible while using this screen function.
 RTG Maintenance Vol 2 – PLC and Display Panel 254

BOGIE SINGLE MODE – SCREEN 21

WARNING ! This function is used only during bogie

malfunction or after bogie position encoder
change. Extra caution shall be taken while
using this function!
Bogie over-travel switches are bypassed.
Use assistant personnel on ground level to
monitor controlled bogie.
Do not use for normal operations!

Operating bogies is possible in the cab only. E-room screen (optional) is for
monitoring and encoder pre-setting only.
Single mode is turned ON automatically by the control system when this page is
selected.
Use following steps to operate single bogie function.
1. Select controlled bogie using F buttons (F1 is bogie #1. etc.). Selected bogie
number is shown on screen (1).
2. Control locking pin up or down by gantry joystick skew function and holding
selected bogie number same time.
Locking pin is automatically stopped when limit switch is activated.
Locking pin position is shown on screen (2). Limit switch value is zero (0) if pin is
on the limit. For example on screen above, locking pin #4 is on up limit switch and
all other locking pins are at middle position.
Skewing clockwise locking pin is controlled to up limit switch.
Skewing counter-clockwise locking pin is controlled to down limit switch.
3. Control bogie turning by gantry joystick left/right function and holding selected
bogie number same time.
Current bogie position is on screen (3) in degrees.
 RTG Maintenance Vol 2 – PLC and Display Panel 255

-Turning bogie to clockwise, deflect gantry joystick to right.

-Turning bogie to counter-clockwise, deflect gantry joystick to left.
Note! Remember always correct bogie turning direction before start
controlling the bogie. Over-travel switches are bypassed!
Pre-programmed position values for each gantry mode is shown on screen (4) in
degrees.
Number “1” starts flashing next to stored position (5), when bogie is so close to
goal position that it is safe to control locking pin down to locked position.
Note! Remember that outer bogies have different “Turn” position value than
inner bogies!
4. To control another locking pin/bogie, repeat the steps 2 & 3.

BOGIE ENCODER PRE-SET AFTER MALFUNCTION

Bogie encoder pre-set function is used after changing the encoder, gateway or cable
for encoder. This function is possible from both panels.
After encoder is changed its position need to be programmed to PLC memory.
Programming is only possible if bogie is at normal position, locking pin is locked and
bogie alignment switch in cabin is at normal position.
Note! Make sure that bogie is at normal position before using this function.
- To restore each bogie encoder value to indicate the correct wheel position mode
(normal/cross/turn/park) F12-key is used while Single Mode screen selection
active
- Now each bogie angle value at normal position shows 0.0 degree (to check
select each bogie to display actual values)

DRIVES ON/OFF CONTROL – SCREEN

This screen is available in the e-room screen (optional) only.

Switch on Maintenance Mode with the selection switch inside the E-room PLC
cabinet.
 RTG Maintenance Vol 2 – PLC and Display Panel 256

Screen Function Action

Label Key
ON F11 When this function key is pressed, the PLC controls main
contactor on.
OFF F12 When this function key is pressed, the PLC controls main
contactor off.
 RTG Maintenance Vol 2 – PLC and Display Panel 257

ACM FINE TUNING – SCREEN 103

N Before using ACM fine tuning

O function, check pulse feedback from
T encoder to inverter, brake function
E and ACM inverter parameters!
!

This screen is shown in the E-room (optional) and Cabin screens when logged in
maintenance level password.

To set more on ACM follow steps below:

1. Select page 103 (ACM Fine tuning).
2. Use arrow –keys to select ACM machinery to be adjusted.
3. Type correction factor using numeric keypad and press Enter.
4. Correction factor has now changed to add more tension to adjusted ACM
machinery.

Note! Correction factor is limited between 1.0 - 1.5.

 RTG Maintenance Vol 2 – PLC and Display Panel 258

LOAD CELL CALIBRATION – SCREEN 104

W Using this load cell calibration

A procedure crane actual load can
R be adjusted. Take extra caution
N when using this calibration!
I Too small spreader weight
N
setting is not making the crane
G
faster!
!
This screen is shown in the E-room (optional) and Cabin screens when logged in
maintenance level password.

Calibrate load cells by following steps:

1. Select page 104 (Load cell calibration).
2. Hoist EMPTY spreader approx. 14 meters (~46 ft). Top right corner shows
hoist position in meters (item ).
3. Turn ‘Maintenance mode’ ON (key-switch or using screen 115). Wait few
seconds ACM to be stopped.
4. Hoist spreader up approx. 15 meters (~49 ft), so that ACM ropes are tight
and main hoist ropes are slack.
5. Press function -key ‘F11’ (Set zero) to set ALL load cells to zero. Offset
values are automatically set by PLC (item ).
6. Lower spreader down to approx. 12 meters (~39 ft), so that main hoist ropes
are all tight and ACM ropes are slack.
7. Calculate load force (kN –value) using converter (item ) on top left corner
on screen. Using numeric keypad type value in metric tons and press
‘Enter’ (i.e. 9.9 metric tons equals 12.14kN). Savannah RTGs head block
and spreader weight is 9.9 metric tons.
 RTG Maintenance Vol 2 – PLC and Display Panel 259

8. Select ‘SET LOAD’ parameters on screen using arrow –keys (item ). Type
load value and press Enter. Repeat this on all rows.
9. Press function –key ‘F12’ (Set Gain) to set load gain. Used load values are
automatically set by the PLC.
10. Returning back to original load cell values press function –key ‘F9’ (Set
Default). Or if gain values are too high, press F9 and start calibration over
again.
11. Hoist up to 14 meters (~46 ft) and turn maintenance mode off.

LC load (kN) Input for PLC from load cells.

Zero offset [kN] Offset value that has set to PLC from original zero values.
Gain Gain value for load after calibration.
Set load [kN] Load under spreader including spreader and head block weights.
Used load [kN] Used load values in PLC software.

MAINTENANCE MODE CONTROL – SCREEN 115

This screen is available in the Operator’s cabin screen only.

Thru this page the ‘Maintenance Mode’ can be controlled on.

Function F12 has toggle function to set maintenance mode on and off when
pressed.

Screen Function Action

Label Key
M-mode F12 When this function key is pressed first time, the PLC
ON/OFF controls maintenance mode on.
When this function key is pressed second time, the PLC
controls maintenance mode off.
 RTG Maintenance Vol 2 – PLC and Display Panel 260

LIMIT SWITCH BYPASS – SCREEN 116

W These functions are used only to

A finish current shift.
R Repair faulty switch as soon as
N
possible.
I
N When anti – collision bypass is
G used, the greater is the risk of
collision damage or an accident
! when approaching a real obstruction
or a person on the site runway.
When ultra sonic are bypassed,
obstruction or a person don’t stop
the crane!

This screen is available in the Operator’s cabin and E-room (optional). Ultrasonic
bypass is only on E-room panel. Shown only when logged in with maintenance
password.
Note! Ultrasonic bypass function only in E-room panel!

Thru this page some of the limit switches can be bypassed. Select limit switch by
arrow –keys and press Enter. Select ‘bypassed’ or ‘Normal’ –function from the list.
Press enter after selection.

Note! Bypass is on until controlled back to Normal function!

 RTG Maintenance Vol 2 – PLC and Display Panel 261

SETTING OP. PANEL PASSWORD

Adding new or changing the passwords in Operator’s panel, the following steps must
be taken:
Arrow keys are used to change cursor positions on this page.

ADDING NEW PASSWORDS ON PANEL

1. Type password level 9 password (supervisor, normally 1808). After Enter –key in
start screen appears “Edit ID number” –text.
2. Select ‘Edit ID Number’ -row by arrow down ▼. Using numeric keypad, type
password and press Enter (i.e. type 1111 and Enter).
3. Select arrow right ► to edit level. Using numeric keypad, type level for password
and press Enter (e.g. type 1 and Enter). Level 1 for operators and level three for
maintenance.
To add more codes to panel select ‘Edit ID number’ –row and repeat steps 2 and
3.
4. It possible to edit Crane identification number selecting ‘Crane ID’ –row by arrow
down ▼. Using numeric keypad, type number and press Enter (i.e. type 8019 and
Enter).

Letters instead of numbers

If crane ID use letters instead of numbers, use following instructions to change
numbers to letters and vice versa. After typing the code press Enter.
A-Z
Press "A-Z" key button to select letter in use instead of
numbers. By pressing once "A-Z" key, left side led is lit and
left letter are in use. Pressing second time this button, right
side letter are in use.
A-Z Press the "CANCEL A-Z" key to return the keypad to numeric
entry mode (i.e. numbers 0...9).
5. Check ID code list by pressing function key F9 on start screen. Top left corner
window shows all ID codes what are stored in panel memory except level 9. Push
ESC to close ID code window.
 RTG Maintenance Vol 2 – PLC and Display Panel 262

Note! After downloading software to OP-panel, all ID codes are deleted from
panel memory. Only the level 9 is in use.

Changing/deleting passwords on panel

It is possible to delete not used or wrong passwords on panel using following steps:
Type password level 9 password (supervisor, normally 1808). After Enter –key in
start screen appears “Edit ID number” –text.
Select ‘Edit ID Number’ -row by arrow down ▼. Using numeric keypad, type the
password that is desired to be erased and press Enter (i.e. type 1111 and Enter).
Select arrow right ► to edit level. Using numeric keypad, type level ‘0’ for password
and press Enter. Now password is erased.
 RTG Maintenance Vol 2 –Special Procedures – Conversion Tables

APPENDIX A. CONVERSION TABLES