EMM_41360-41373_GB.pdf

Rubber Tyred Gantry Crane Kalmar E-one 2 412321-8L-2040C-ZE

Maintenance Manual

19.10.2015

s/n 41360-41373 2015 Original Instructions

A Foreword B Safety C Preventive maintenance 0 Complete machine

Maintenance manual

1 Cummins 2 Transmission 3 Driveline/axle 4 Brakes 5 Steering 6 Suspension 7 Load handling 9 Frame, body, cab and accessories 11 Common electrics F Technical data G Index

1

Table of content A Foreword

3

Maintenance manual

3

Reading this manual

5

Feedback

7

Maintenance manual 308 001 EN

2


A Foreword – Maintenance manual

A

3

Foreword

Maintenance manual General Read the instructions in this manual carefully, and follow them strictly so that the safety and reliability of the machine will be main‐ tained at the intended level. Contact your superior if some parts of this manual lead to questions or some important information seems to be missing. We thank you for selecting Cargotec Finland Oy as the provider of your machine. We believe that we can fulfil your expectations with regard to the operational features and availability of maintenance services.

Contents This maintenance manual contains the following information:

Foreword

General information about the purpose and contents of this maintenance manual, instructions for reading the manual, and a form for giving feedback and correcting any inaccuracies.

B

Safety

Information regarding safety.

C

Preventive maintenance

Information about preventive maintenance. Maintenance tables.

0

Complete machine

1

Engine

2

Transmission

3

Driveline/Axle

4

Brakes

5

Steering

Technical description, information about the machine structure and functions, and function-specific troubleshooting instructions. Each subfunction describes the components related to the function in question. The most common components are thus mentioned in several sections, but they are usually described in connection with the first function to which the component is related. In addition to the general description, there is also a detailed description of the issues typical of the subfunction. The next subfunction using the same component has descriptions of the components relevant to the new function only. Instructions for service procedures.

6

Suspension

7

Load handling

9

Frame, body, cab and accessories

11

Common electrics

F

Specifications

Technical specifications, conversion tables, unit conversion factors.

G

Terminology and index

General terms and abbreviations, their explanations, index of headings.

A


4

A Foreword – Maintenance manual

Division into function groups The division into function groups is the same for all machines manu‐ factured by Cargotec Finland Oy. The groups are indicated by num‐ bers with two digits (e.g., 4.3 Power-assisted brake system). Machine-specific adaptations of the function groups are indicated by a third or fourth digit (e.g., 4.3.9 Wheel brake or 4.3.9.1 Disc brake). This results in certain headings (function groups) being omitted in the documentation for certain machines since the machine lacks that particular function. This means that there may be gaps in the function group numbering (e.g., 2.7 Cooling system may be inclu‐ ded for certain machines, but may be missing for other machines). References between different manuals (operator's manual, mainte‐ nance manual, and workshop manual) are used since the different manual types have different purposes and thus different information content. References between sections within this maintenance manual are indicated with the chapter and section number, e.g., "See Chapter 4, Brakes, Section 4.3.9., Wheel brake".

Conditions The instructions are based on the use of generally available stand‐ ard tools. All lifting devices, e.g., slings, straps, and ratchet blocks, must meet the national standards and regulations for lifting devices. Cargotec Finland Oy will not accept any responsibility for modifica‐ tions performed without permission from Cargotec Finland Oy, or if lifting devices, tools, or work methods other than those described in this manual are used.

Storage Keep the manual in good condition, and store it in a place where it is always available to the service personnel.

About the machine The information in this manual corresponds to the basic design and appearance of the machine at the time of delivery. Due to customer adaptations, there may be variations and/or deviations. Cargotec Finland Oy reserves the right to modify specifications and equipment without prior notice. All information and data in the man‐ ual are valid at the time of publication.

Copyright This document may not be copied, presented, or delivered to a third party without our explicit permission, or used for purposes other than those allowed by us. We reserve the right to alter the adjustment values, equipment, and service and repair instructions for the machine without prior notice. Cargotec Finland Oy


A Foreword – Reading this manual

5

Reading this manual Information on possible safety hazards This manual includes three types of warnings containing instructions on how to avoid situations that may compromise safety.

DANGER Warns of a situation that involves immediate risk of personal injury or death if the safety instructions provided are not observed.

WARNING Warns of a situation that may cause personal injury, death, and/or substantial damage to the machine or other property if the safety instructions provided are not observed.

CAUTION Warns of a situation that may cause moderate personal injury and/or damage to the product or other property if the safety instructions pro‐ vided are not observed.

Important information The word NOTE is used to emphasise issues concerning safety or the maintenance instructions to which special attention must be paid while working on the machine. An example of how the word NOTE appears is presented below.

NOTE Calls the reader's attention to an instruction that, e.g., emphasises operational safety.

Optional equipment

Fig. : The symbol indicates an optional equipment.

The machine can be equipped with various accessories or optional equipment. The equipment is marked with the symbol seen on the left. The symbol is always accompanied with text representing and/ or describing the equipment. The NOTE symbol is clearly distinguished from the text, and it is placed next to the text and picture representing the equipment.


6

A Foreword – Reading this manual

Function descriptions The function descriptions are presented as overviews in a chart for‐ mat that describe the function and the associated components and signals. The function descriptions describe the function in a logical order from the input signal to the output signal. Most functions require that certain preset conditions be met before the function can be activa‐ ted. In these cases, the required conditions are listed above the fig‐ ure. The function descriptions use symbols to depict components like valves and sensors. An example of a function description is provided on the following page.

Manual package The following manuals are included in the machine delivery as ordered: • • •

Operator's manual Maintenance manual Spare parts catalogue

Each manual can be ordered separately, in case extra copies of instruction manuals or spare parts catalogue for the machine are needed later.

Ordering the manuals The manuals can be ordered from Cargotec Finland Oy's spare parts department. Refer to the publication number of the manual when placing the order.


A Foreword – Feedback

7

Feedback Form for copying It is the goal of Cargotec Finland Oy to provide everyone working on the maintenance of Kalmar machines with access to the correct information. Your feedback is important for us to be able to improve the informa‐ tion. Copy this form, write down your views, and send it to us. Thank you for your participation!

To:

Cargotec Finland Oy Product Support P.O. Box 387 FI-33101 Tampere FINLAND Fax: +358 3 265 8220

From:

Company / sender: ............................................................................................................................... Telephone:............................................................................................................................................ E-mail:................................................................................................................................................... Date: .................................... - .................. - ........................................................................................

Manual information

Name / publication number:..................................................................................................................

Suggestions, comments, remarks, etc.

..............................................................................................................................................................

Chapter / page number:........................................................................................................................

.............................................................................................................................................................. .............................................................................................................................................................. .............................................................................................................................................................. .............................................................................................................................................................. ..............................................................................................................................................................


8

A Foreword – Feedback


1

Table of content B Safety

3

General safety instructions

3

Safety instructions Service Position

4 4

Electric systems

4

Several mechanics working on the machine

7

Working on top of the machine

7

Working under the machine

8

Lifting heavy components

8

Vibration

9

Noise

9

Solvents

9

Fire and explosion risks

10

Fluid or gas under pressure

11

Coolant

12

Refrigerant

12

Air pollution

12

Tensioned springs

13

Rotating components and tools

14

Tyres

14

Regulations for safe maintenance work

15

Concerning the maintenance and repair personnel

16

Instructions for using shore supply (if equipped)

17


2


B Safety – General safety instructions

B

3

Safety

General safety instructions General Everyone performing maintenance and adjustment procedures on the machine must follow the safety instructions included in this man‐ ual. Maintenance must be carried out by professional and trained per‐ sonnel only. Training on maintenance and occupational safety issues can be ordered from our product support department if necessary. Remember: • •

• • •

Follow the safety instructions included in this manual. Obtain the training required by the job and, if necessary, ask your work instructor for guidance on the issues regarding safety at work. Follow local laws, safety instructions, and regulations. Do the job with equipment and tools that you have been trained to use safely and properly. Work carefully but efficiently, and do not take any risks.

In this publication, Cargotec Finland Oy. has documented and warned about situations and risks that may occur in connection with operation as well as service and repairs of the machine under nor‐ mal conditions. Therefore, it is very important that all persons working on the machine acquaint themselves with and act according to the informa‐ tion in the maintenance manual and operator's manual.


4

B Safety – Safety instructions

Safety instructions General Read the safety instructions before starting servicing or other work on the machine, and follow them strictly to keep operational safety at the intended level.

Service Position General The machine's service position is used during servicing, mainte‐ nance, and other procedures during which the machine must be sta‐ tionary Service position: • • • •

The machine is parked, and the parking brake is engaged. The spreader has been lowered fully. The engine is off. The main power is off.

Electric systems DANGER

DANGER The electric systems must be serviced and repaired by trained serv‐ ice personnel. Electric systems of the machine • • •

High-current system 400/440 VAC Frequency 50/60 Hz Main power supply from external power source (zero emission RTG

), see chapter F Technical data.

Risks When using shore supply, there are energized parts in the machine although the main switch is off. Danger of electric shock if energized electric centre components are touched. Danger of electric shock if cables are damaged. Danger of electric shock if voltage is switched on unexpectedly. Danger of electric shock if components energized by shore supply are touched. Battery acid splashing on the skin or in the eyes. Burns caused by short circuit when handling batteries.



5

Precautions •

• •

• • •

•

Before commencing work, ensure that the electric system is de-energized. The high-current system includes components that remain energized for several minutes after the engine is stopped. Wait for 10 minutes after stopping the engine before commencing work on the electric system. Ensure that machine components are not energized by shore supply. Inform other people of the servicing being performed. Place signs prohibiting the switching on of power in the appropriate places. Regularly check the condition of the machine cables and the shore supply cable. Handle the batteries carefully. While working on the batteries, remove your watch, rings, and other metal objects that could cause a short circuit. Use insula‐ ted tools. Working with the hydraulic system: when system is turned off and main current broken there is no residual pressure in the hydraulic system.

Zero emission RTG (option) Power supply to the zero emission RTG following voltage levels: • •

can be provided with

Over 1 kV (medium voltage), crane is equipped with medium voltage transformer Below 1 kV (low voltage)

Refer to chapter F Technical data for the power supply voltage of the crane. Protection against direct contact of power supply



6

DANGER Do not open cable reel slipring housing (A) if the power supply cir‐ cuits are live. Over 1 kV power supply: Do not open transformer housing if the power supply circuits are live.

A

Transformer location varies depending on crane’s equipment, see Operator’s manual. When the crane main switch is switched off, power supply circuits from the land feeding point to the crane main switch are still live if the main power supply is not switched off from the land feeding point. Land feeding point: Before commencing any maintenance or repair of equipment in the power supply circuit, always ensure the main power supply is switched off from the land feeding point switchgear. The switchgear must be locked, maintenance earthed and marked with appropriate maintenance work warning sign. The safety instructions of the switchgear manufacturer must be followed to ensure the safe opera‐ tion procedures. Crane: Crane main switch must be opened, locked to open position and marked with maintenance work warning sign. Protection against indirect contact of power supply

DANGER There must be an earth fault monitoring device on the land feeding point switchgear. In case of earth fault it will immediately open the crane main switch.

Clothing Wear appropriate work clothing. Remove loosely hanging clothing (tie, scarf, etc.). Do not wear clothes with wide sleeves, wide trouser legs, etc. Remove jewelry as it may get caught in moving parts. Long hair must be tied up securely, otherwise it may easily get caught in moving parts. Be careful when performing welding and flame cutting work since hair catches fire easily.



7

Several mechanics working on the machine DANGER

WARNING Be especially careful if several mechanics work on the machine at the same time. Communicate so that everyone knows where the others are and what they are doing. Risks Falling objects, such as tools, cause a risk of injury. Movements performed by the operator, e.g., movement of lifting equipment, may cause severe personal injuries. Precautions • • • • • •

Ensure that the spreader has been fully lowered or secured in some other manner. Only one person at a time is allowed on the ladder. Do not leave objects in places from which they may fall when, for example, the machine is moved. No personnel are allowed in the operating range of the rope system and the ropes during the operation of the machine. Be aware of the risks when several persons work around the machine. Make your co-workers aware of what you are working with.

Working on top of the machine

NOTE Always use trolley locking device during maintenance. Risks Oily platforms and ladders cause a risk of slipping and falling while moving on the machine. The risk of falling is high, especially when moving and working out‐ side of the handrails. Precautions • •

Carefully clean all platforms, walkways, and ladders to prevent the risk of slipping. Always wear a safety harness when working outside of the handrails.


8


Working under the machine Risks The spreader may be lowered and cause a risk of injury. Precautions •

Ensure that the spreader has been fully lowered or secured in some other manner.

Lifting heavy components WARNING

WARNING Careless handling of heavy components can lead to serious personal injury and material damage. Use type approved lifting tools or other devices to move heavy com‐ ponents. Ensure that the device is stable and intact. Risks

WARNING Careless handling of heavy components can lead to serious personal injury and material damage. Use type approved lifting tools or other devices to move heavy com‐ ponents. Ensure that the device is stable and intact. Unsuitable lift slings, straps, etc. may break or slip. The centre of gravity (balance point) of the component can change during the course of the work, and the component may then make unexpected movements which may cause severe personal injuries and material damage. A component lifted with lifting equipment can start to turn if the bal‐ ance is upset. A component lifted using an overhead crane may start to swing back and forth, which can cause a risk of injury. Lift using a lifting device. •

Use lifting tools or equipment, especially when such equipment is available for specific work operations.

If lifting must be performed without a lifting device: • •

• •

Lift near your body. Keep your back straight. Raise and lower with your legs and arms, do not bend your back. Do not rotate your body while lift‐ ing. Ask for assistance in advance. Wear gloves. Gloves provide good protection against minor crushing injuries and cuts to fingers. Always wear protective shoes.



9

Vibration General In case of long-term use of vibrating tools, for example, percussion drills or grinders, injuries may be sustained as vibrations are trans‐ mitted from tools to hands. This happens especially when the fin‐ gers are cold. Precautions • • •

Use heavy gloves to protect against cold and vibrations. Switch between work duties to give your body time to rest. Change your working position and grip so that your body is not stressed in only one position by the vibrations.

Noise General Noise louder than 85 dB (A) that lasts longer than 8 hours is consid‐ ered harmful to hearing. Tones at high frequencies are more dam‐ aging than low tones at the same sound level. Impact noise can also be hazardous, e.g., hammer blows. Risks Hearing damage can occur at noise levels higher than the limits. In severe cases, hearing damage can become permanent. Precautions •

Use hearing protection. Ensure that it has been tested and pro‐ tects against the noise level in question.

Solvents General Fluids that (as opposed to water) dissolve grease, paint, lacquer, wax, oil, adhesive, rubber, etc. are called organic solvents. Such liquids include white (petroleum) spirits, petrol, alcohols, die‐ sel, xylene, trichloroethylene, and toluene. Many solvents are flammable and constitute a fire hazard. Risks Products containing solvents produce vapours that can cause dizzi‐ ness, headaches, and nausea. They may also irritate mucous mem‐ branes in the throat and respiratory tracts. If solvents come in direct contact with the skin, this may cause dry‐ ing and cracking. The risk of skin allergies increases. Solvents may also cause injury if they penetrate through the skin and are absor‐ bed by the blood. If the body is continuously exposed to solvents, the nervous system may be damaged. Symptoms include sleep disorders, depression, nervousness, poor memory, or general tiredness and fatigue. Con‐ tinuous inhalation of petrol and diesel fumes is suspected to cause cancer.


10

B Safety – Safety instructions Precautions •

• • • • •

Avoid inhaling solvent fumes and ensure good ventilation. If necessary, wear a fresh-air mask or respiratory device with a suitable filter for toxic gases. Never leave a solvent container open; seal the lid carefully. Use solvents with a low content of aromatic substances. This reduces the risk of injuries. Avoid skin contact. Use protective gloves. Make sure that work clothes are solvent-resistant.

Fire and explosion risks General Examples of explosive substances are oils, petrol, diesel fuel, organic solvents (lacquer, plastic, cleaning agents), rust proofing agents, welding gas, gas for heating (acetylene), and high concen‐ trations of dust particles from combustible materials. Rubber tyres are highly flammable and cause fires that spread explosively. Risks Examples of the causes of ignition include welding, cutting, smok‐ ing, sparks produced by grinding, and flammable materials coming into contact with hot machine parts. Petrol fumes, for example, are heavier than air and can thus run down a sloping grade or down into a grease pit where, e.g., welding flames can cause an explosion. Evaporated petrol has a very pow‐ erful explosive force. Special cases Diesel fuel oil with added petrol has a reduced flash point. There is an explosion risk even at room temperature. The explosion risk due to warmed diesel fuel oil is greater than for petrol. When changing oil in the engine, hydraulic system, and transmis‐ sion, keep in mind that the oil may be hot and can cause burn inju‐ ries. Welding on or near the machine: If diesel or other oils have leaked out and have been absorbed by rags, absorbing agent, paper, or other porous material, welding sparks can cause ignition and an explosive spread of fire. When a battery is being charged, the battery electrolyte forms hydrogen gas, which is highly explosive. The risk of explosion is especially high when a booster battery or a rapid-charge unit is used, as these increase the risk of sparks. Today's machines contain a lot of electronic equipment. During welding, the control units and battery cables must be disconnected. Otherwise, strong welding currents can short-circuit the electronics, destroy expensive equipment, and may also cause an explosion or fire. Welding work must never be carried out on painted surfaces (remove paint by blasting at least 200 mm around the welding or cutting point). Use gloves, respiratory protection, and protective safety glasses. Also, welding work must never take place near plas‐ tic or rubber materials without first protecting them from the heat. Maintenance manual 308 001 EN


11

Paints, plastics, and rubber generate various substances when heated that may be hazardous to health. Be careful with machines that have been exposed to intense heat or fire. Precautions • • • • •

•

Store explosive substances in approved and sealed containers. Ensure that there are no ignition sources near flammable or explosive substances. Ensure that ventilation is adequate or there is an air extraction unit when handling flammable substances. At high temperatures epoxy paint releases toxic gases. During repair welding adequate ventilation has to be ensured. Inhaling epoxy paint fumes irritates respiratory organs and mucous membranes in the nose and the throat. During painting ensure good ventilation. Before starting welding or other thermal work in the power unit, check and / or repair all fluid and oil leaks and clean the work‐ ing area carefully.

Fluid or gas under pressure General Pressure lines can be damaged during work, and fluid or gas can stream out. There may be high pressure in a line even if the pump has stopped. Therefore, gas or fluid can leak out when the connection to the hose is loosened. Risks There are injury risks in connection with work on: • • • •

hydraulic and brake systems fuel system tyre repairs air conditioning system

Precautions • • • • • • •

•

Use safety glasses and protective gloves. Never work on a pressurized system. Never adjust a pressure relief valve to a higher pressure than recommended by the manufacturer. Damaged hydraulic hoses must be replaced as soon as possi‐ ble! Check connections thoroughly. Use fluid when checking for leaks. Never blow clothes clean with compressed air. Discarded accumulators must first be punctured before they are deposited as waste (to avoid risk of explosion). Carefully drill a hole with 3 mm diameter after depressurizing. Never use your hands to detect a leak. A fine high-pressure stream from a hydraulic hose can easily penetrate the skin and cause very severe injuries.


12


Coolant General The coolant in the machine's cooling system consists of water, anticorrosion compound, and (when needed) antifreeze fluid, for exam‐ ple, ethylene glycol. Coolant must not be drained into the sewer system or directly onto the ground. Risks The cooling system is pressurized when the engine is warm. Hot coolant can jet out and cause scalding in case of a leak or when the expansion tank cap is opened. Inhaling ethylene glycol and anti-corrosion compound is dangerous and hazardous to health. Precautions • • •

Use protective gloves and safety glasses if there is a risk of splashing or spraying. Carefully open the filler cap first to release the excess pres‐ sure. Be careful; hot steam and coolant may stream out. If possible, avoid working on the cooling system when the cool‐ ant is hot.

Refrigerant General Refrigerant is used in the machine's air conditioning system. Risks The air conditioning system operates at high pressure. Escaping refrigerant can cause freeze burns. Heated refrigerant (e.g., during the repair of leaks in the air condi‐ tioning system) produces gases that are very toxic if inhaled. Precautions •

• •

The air conditioning system must be serviced by authorized and trained personnel only. Follow national legislation and local regulations! Use protective gloves and safety glasses if there is a risk of leaks. Make sure that there are no heat-producing sources or objects close by (cigarette glow, welding flame).

Air pollution General Air pollution is the impurities in the air that are regarded as hazard‐ ous to health. Certain pollution is more prominent in certain environ‐ ments. The following air pollution hazardous to health is especially promi‐ nent in workshops:



• • • • •

•

13

Carbon monoxide (fumes): Present in exhaust fumes. Odour‐ less and therefore especially dangerous. Nitrogen oxides (nitrous gases):Present in exhaust fumes. Welding smoke: Especially hazardous to health when welding on oily surfaces, galvanized, or lacquered materials. Oil mist: For example, when applying anti-corrosion agent. Grinding dust and gases: Generated when grinding and heat‐ ing plastics, lacquer, anti-corrosion agents, lubricants, paint, etc. Isocyanates: Present in certain paints, fillers, adhesives, and foam plastics.

Risks Sulphuric acid mist is corrosive and injures the respiratory tracts. Sulphuric acid is generated when heating certain plastics and paints. Isocyanates can be released in the form of steam or dust when cut‐ ting, grinding, or welding. Isocyanates may also be present in aero‐ sols. They can irritate mucous membranes, producing symptoms similar to asthma and impairing lung function. Even brief exposure to high concentrations can cause problems of persistent high sensi‐ tivity. Precautions • •

• • •

Ensure adequate ventilation during welding, charging a battery, and other work where hazardous gases are generated. Use suitable gloves and respiratory protection when there is a risk of oil mist. Ensure that the protective equipment is oilresistant. Apply oil-resistant protective lotion to unprotected skin. Ensure that an eye-wash station is in the immediate vicinity when working with corrosive substances. Avoid unnecessary operation of the machine inside the work‐ shop. Connect an air extractor to the exhaust pipe so that the exhaust fumes are removed from the workshop.

Tensioned springs General Examples of tensioned springs: • • • •

suspension elements in rubber suspension return springs in the parking brake cylinder lock rings gas springs

Risks If a tensioned spring is released, it is shot out by the spring force and can also take adjoining parts with it. Small springs can cause eye injuries. Parking brake springs are tensioned with high force and can cause very severe injuries if they are accidentally released in an uncontrol‐ led manner.


14

B Safety – Safety instructions Gas springs are tensioned with high force and can cause very severe injuries if they are accidentally released in an uncontrolled manner. Precautions • • • •

Use safety glasses. Lock rings should be of a suitable type and in good condition. Follow the instructions in this and other manuals when per‐ forming maintenance. Always use the recommended tools.

Rotating components and tools General Examples of rotating components and tools: • • • • •

cooling fan drive belts drive shafts drills grinders

Risks Rotating components, for example, fans or shafts, can cause severe injuries if touched. Drills, grinders, and other machines with rotating parts can cause severe injuries if clothes or hair get caught and are wound up in the machine. Precautions •

See Clothing on page 6

Tyres DANGER

DANGER Tyres should be regarded as pressurized containers. They constitute a risk of injury if handled incorrectly. Never repair damaged tyres, rims, or lock rings. Tyre repairs should only be performed by authorized service personnel. Risks Dismantling wheels: Tyres, rims, or lock rings can be thrown. Inflating tyres: Tyres, rims, or lock rings can be thrown. Precautions • • •

Deflate the tyre before starting to work on the wheel. Check that tyres, rims, and lock rings are intact. Never repair damaged tyres, rims, or lock rings. Use a protective screen and safety glasses.



15

Regulations for safe maintenance work General Thoroughly acquaint yourself with the RTG structure and the manuals. Observe the instructions and warnings. 2. Try to determine the hazards, and avoid them. Report any faults that you have noticed to your superior or to the person in charge of repairs. 3. Fall protection: Working at heights on cranes or hoists, all per‐ sons shall wear safety harnesses that are fitted with a rope and securely attached to a structural member of the crane. 4. Always use on protective clothing, overall, helmet, gloves, safety shoes and etc. 5. Always observe sufficient caution and care when climbing into or coming down from the RTG. Always move along the paths designated as walkways. Keep the walkways clean. Remove all safety risks, such as snow and ice, and other foreign matter. Wipe away all oil leakages at once to prevent slipping. 6. Keep the RTG clean, especially the adjusting and control devi‐ ces. 7. Do not allow any unauthorized persons to operate the RTG entrusted in your use. The operator of the RTG is responsible for any damage caused by the machine. 8. Acquaint yourself in advance with the use of emergency exits. 9. Do not stand under a hanging container or load. 10. If problems arise, remember to stay calm. Think first, and then act accordingly. 1.


16


Concerning the maintenance and repair personnel General 1.

2.

3. 4. 5. 6. 7. 8.

9. 10. 11. 12. 13. 14.

15.

16. 17. 18. 19. 20. 21.

22. 23. 24.

The service and repair personnel of the RTG is responsible for that the machine doesn’t cause damage to other persons in connection with the service or repair work. Be especially careful when you do maintenance work in abnor‐ mal conditions that require special working methods, for exam‐ ple, replacing the hoist ropes. Before starting off, make sure that nobody is standing in front or behind the RTG. Avoid sudden stops and starts. Always perform the maintenance and repair work according to the instructions given. By observing a danger spot, immediately report to the person responsible for safety. The machine must not be handed over for operation, until the observed faults and damages have been repaired. Observe the signs and instructions indicating free height. You should know the exact total height of your RTG before driving into places with restricted free height. Be especially careful with temporary structures, hanging overhead power lines, etc. Watch out also for objects at cabin height. You may perform the service and repair work only in compli‐ ance with your actual qualification. Don’t try to guess! Maybe you make a wrong guess, causing a possible danger to yourself and the other personnel. If necessary, consult a person being aware of how to proceed. When servicing pressurized systems, proceed very carefully. Non-discharged energy sources always are hazardous. Follow unconditionally the instructions given. If it is necessary to remove protective guards during the serv‐ ice, place warning signs and take other measures to protect other persons from danger. When changing driving direction, stop the carrier completely with the service brake before moving the direction selector lever. Watch out for the edges of driveways where the surface may be yielding and cause the danger of overturning. Remember that the RTG is not intended for carrying persons. Always stop the engines whenever you leave the RTG even for a short while. Lower any load to the ground. Make a detailed report on any collisions, including the damage caused. This could prevent accidents from being repeated. Observe the weight of your RTG , and its total weight loaded. Do not drive on surfaces with insufficient load capacity. If starting spray is used to aid cold-starting, strictly follow the instructions on the use of these aerosols given later in this manual. Follow the periodic maintenance schedule. This ensures that the controls and the whole RTG operate reliably and safely. The engines must always be stopped when service or inspec‐ tions are being carried out. The use of open flame is absolutely forbidden when checking fuel or battery electrolyte levels.



17

25. The radiator is pressurized when the coolant is hot - open the radiator cap slowly and cautiously. 26. Hot exhaust pipe cause burns, extreme carefulness required. 27. Do not open the main switch when the engines are running. 28. Only authorized electricians can do maintenance for electrical systems and open electrical boxes. Never do any maintenance work when parts are live. Special carefulness with charged components such as condensators of drive converters is required. 29. Only a person that is well acquainted with the RTG’s control and the cabin equipment is allowed to be in the cabin during service and repairs. 30. Working with the hydraulic system: always have the system turned off and main power cut off during maintenance work. Use a pressure gauge to check that there is no residual pres‐ sure in the hydraulic system before starting work on the hydraulics. 31. Driving is forbidden without fastened seat belts. 32. Never park the machine on a inclined plane.

Instructions for using shore supply (if equipped) General

CAUTION Always use shore supply when RTG is not in use. If shore supply is not used, the air conditioning devices do not operate and the electri‐ cal devices may get wet and damaged. Always close the equipment compartments' doors when using shore supply. If use of the shore supply is neglected, it may release Cargotec Fin‐ land Oy from all warranty liabilities. When using shore supply, the following equipment operates when the PLC main switch is off: • •

• •

• •

Sockets (direct feed) All heaters (electrical housings, motors, generators, main die‐ sel, the radiator of the electrical compartment, the radiator in the cabin) (direct feed) Battery charger (direct feed) Air conditioning in the cabin and the electrical compartment (direct feed if the frequency of the machine and the shore sup‐ ply is the same) The lights in the equipment compartments (feed through the light switches) Winch (direct feed to the winch main switch)

When using shore supply, the following equipment operates when the PLC main switch is on: • •

Cabin fans (automatically turns the radiator off - control with the touch panel) All walkway lights (control with the touch panel or the push but‐ tons of the power unit and the rear frame)


18


DANGER Danger when shore supply is on. High voltage 230V/ 400V is on (gantry motors, trolley motor, hoist motor).


1

Table of content C Preventive maintenance

3

For the service personnel

3

Maintenance tables Reading instructions for maintenance table

5 5

Initial checks

5

Daily checks

8

Scheduled maintenance - General

11

Scheduled maintenance - Engine

14

Scheduled maintenance - Driveline / Axle

20

Scheduled maintenance - Bakes

23

Scheduled maintenance - Steering

34

Scheduled maintenance - Suspension

35

Scheduled maintenance - Load handling

37

Scheduled maintenance - Frame, body, cab and accessories

50

Scheduled maintenance - Common electrics

54

Scheduled maintenance - Technical data

60


2


C Preventive maintenance – For the service personnel

C

3

Preventive maintenance

General Follow our maintenance programme carefully to ensure that the operational safety and reliability of the machine are maintained at the intended level. The maintenance programme specifies the inspection and mainte‐ nance procedures as follows: • • •

Daily checks Visual/operating checks Scheduled maintenance

IMPORTANT Maintenance and adjustment procedures must be carried out by pro‐ fessional and trained personnel only. To meet the terms and conditions of the warranty agreement, use only recommended fluids and original equipment and spare parts available from our spare parts department. Following the maintenance programme defined in this maintenance manual is a prerequisite for maintaining the machine warranty.

For the service personnel General The maintenance instructions provide the service personnel with information about the mechanisms and maintenance items of the machine as well as guidelines for safe maintenance. Familiarise yourself with the operation of the machine, the mainte‐ nance programme, maintenance items, and work instructions. Always follow the maintenance instructions. For regular maintenance, use the oils, greases, and fluids specified later in this manual and the filters and other service parts available from our spare parts department. Absolute cleanliness should be observed especially during the regu‐ lar maintenance of the hydraulic and fuel systems to ensure the reli‐ able operation of the machine.

Work premises Perform the maintenance in clean premises to prevent impurities from entering the devices on the machine. Protect the premises against dust from the environment; for example, if sand and metal particles enter the oil and other fluid systems of the devices, severe damage will be caused to the devices.


4

C Preventive maintenance – For the service personnel Ensure that maintenance can be performed without compromising occupational safety. Ensure that the used oils, greases, and fluids are delivered to a haz‐ ardous waste collection point in accordance with the applicable instructions.

Reporting Carefully document the maintenance procedures performed, writing down any defects detected and repairs made. If you notice any defects, immediately inform your supervisor or the person responsible for the maintenance of the machine. The defects must be repaired before continuing to use the machine. Store the reports carefully so that they are easily available when needed.


C Preventive maintenance – Maintenance tables

5

Maintenance tables Reading instructions for maintenance table Reading instructions for maintenance tables

IMPORTANT Following applies when only power source for the crane is a diesel generator: •

All service intervals are based on operating hours of main diesel engine. For operating hours, see “Main diesel hours” counter on the power unit.

Following applies when the crane is powered by external power sup‐ ply (Zero emission RTG): •

•

Service intervals, other than for engine, are based on operating hours while the crane has been powered either by external power supply or by diesel generator. For operating hours, use the sum of “Supply hours” and “Generator hours” counters in the EE-House. Service intervals for engine are based on operating hours of main diesel engine. For operating hours, see “Generator hours” counter in the EE-House.

Initial checks Initial maintenance Maintenance of a new machine during the first 500 hours of opera‐ tion. For reading instructions, see section Reading instructions for main‐

tenance tables.



6

Maintenance item

Service interval / hours of operation

Reference

1 Engine Checking the condition and tension of drive belts of auxiliary diesel

After first 250 operating hours. Replace the belt if it has unacceptable cracks, is frayed, or has pieces of material missing.

Checking the radiator condition of

After first 250 operating hours.

auxiliary diesel 3 Driveline / Axle Changing oil of the wheel hubs (driven and nondriven wheels)


Chapter 3, section 3.3 Driven wheel

Changing oil of driven axle assembly, wheel hub planetary gear drive, interaxle differential, wheel bearing




Chapter 3, section 3.4 Non-driven wheel

3 months after commissioning of the crane.

Appendixes, section Emergency hoist

of

After first 300 operating hours. Tighten if needed.

Bromma spreader manual

Checking the operation of twistlocks of spreader

After first 100 operating hours. Tighten the twistlocks if needed.


Lubrication of spreader

Lubricate and check the various points as per the lubrication instructions after first 50 and 300 operating hours.


Changing the pressure filter(s) of


Appendixes,

NOTE Only 16 wheel RTG

Changing assembly

oil

of

non-driven

axle


4 Brakes Changing oil of hydraulic power unit for the emergency hoist brake

brake

7 Load handling Checking spreader

the

chain

tension

spreader's hydraulic unit


hydraulic unit

section

Spreader


Maintenance item

7


Reference

of


Appendixes,

section

Spreader

Changing the air filter(s) of spreader's


Appendixes,

section

Spreader

Changing

the

return

filter(s)

spreader's hydraulic unit

hydraulic unit Checking during operation of the hoist motor that specified technical data are met (power input, temperatures of windings, bearings, coolants, etc.)


Checking during operation of the hoist motor that running smoothness of machine and running noise of bearings have not deteriorated


Checking during standstill of the hoist motor that no subsidence or cracks have occurred in the foundation


Checking the hoist motor's cables and insulating parts (as far as accessible) are in proper condition and show no signs of discolouration


Changing oil of the trim gear


Cleaning the trim gear housing


hydraulic unit

hydraulic unit

Chapter 7, section 7.2 Lifting/lowering

11 Common electrics the


Chapter 11, section 11.5 Distribution

Checking the strain reliefs of energy





for



Checking the condition of roller links of







Checking

the

condition

of

endpoints of energy chain

chain Checking the wear of energy chain

Checking the energy chain obstructions

energy chain Checking the condition of cables and hoses of energy chain Checking the condition of troughs of energy chain


of electricity

of electricity

of electricity

of electricity

of electricity

of electricity

of electricity

8


Maintenance item


Reference

Checking the operation of moving arm



After first 100 operating hours

Appendixes, Cable reel

of energy chain Changing oil of the cable reel gear Zero emission RTG

of electricity

Daily checks Daily checks

WARNING Never operate a defective machine. If any defects are found during daily inspections, report the defects immediately to your superior or those responsible for the machine's maintenance. Daily check of the machine is extremely important to ensure efficient and safe operation. It is recommended that the operator or the person responsible for the maintenance of the machine carry out the inspections before each shift. This way it can be ensured that work does not com‐ mence with a defective machine. For reading instructions, see section Reading instructions for main‐

tenance tables.



Item

Inspection method

Note

9

Reference

General Oil and fluid leaks

Visually

1 Engine section

1.8

1, section Cooling system

1.7

Oil level

Dipstick

Chapter

Coolant level

Visually

Chapter

Air filter

Visually

The filter must be changed if the clog warning indicator shows completely red.

Chapter 1, section1.6 Air intake/exhaust outlet

prefilter/water

Visually

Remove water if necessary.

Chapter 1, section 1.2 Fuel system

Condition and tension of drive belts

Visually

Replace the belt if it has unacceptable cracks, is frayed, or has pieces of material missing.

Leakage of charge air pipe

Visually/audio check

Shields and doors

Visually

Fuel separator

•

Closed and correctly

1, Lubrication

Chapter 1, section 1.6 Air

intake/exhaust outlet

locked

Coolant level of auxiliary

Visually

diesel Supply and fuel level of

Visually

auxiliary diesel Oil level of auxiliary diesel

Dipstick

Condition and tension of drive belts of auxiliary diesel

Visually

Every 250 operating hours. Replace the belt if it has unacceptable cracks, is frayed, or has pieces of material missing.

Radiator

Visually

Every 250 operating hours.

condition

of

auxiliary diesel 3 Driveline / Axle Oil leaks

Visually


10

Item


Inspection method

Note

4 Brakes Operation of gantry brakes

Brake test immediately after moving off.

Checking condition of oil in the hydraulic power unit for the emergency hoist brake.

Sight glass.

Change the oil if it contains water or other impurities.

5 Steering Operation of steering gear

Visually

Oil leaks of steering gear

Visually

6 Suspension Wheel pressure and condition, wheel attachment

Visually

Every 300 operating hours, check the tyre pressure.

NOTE It's normal for tyre pressure dropping by 5% in a month.

7 Load handling Oil level of skew gear

Sight glass

Oil leaks of skew gear

Visually

Noise of skew gear

Audio check

Oil level of trolley gear

Sight glass

Oil leaks of trolley gear

Visually

Oil temperature of trolley gear

Visually

Noise of trolley gear

Audio check

Oil level of hoist gear

Sight glass

Oil leaks of hoist gear

Visually

Oil temperature of hoist gear

Visually

Noise of hoist gear

Audio check


Reference


Item

Inspection method

Ropes for possible damage and change in shape

Visually

Spreader and lifting devices

Visually

Position sensors of spreader

11

Note

Reference

Visually

Clean if needed


Chain tension of spreader

Visually

Every 300 operating hours. Tighten if needed


Operation of twistlocks of spreader

Visually

Every 100 operating hours. Tighten the twistlocks if needed


Oil level of hydraulic system

Sight glass

of spreader Oil temperature of hydraulic

Visually

system of spreader 9 Frame, body, cab, and accessories Controls, instruments, and indicator lights

Visually

Operation check before and after starting the engine

Operation of flashing beacons and buzzers

Visually or by listening

Cleanness of cabin windows

Visually

Clean if required

11 Common electrics Covers and doors of electric centres •

Closed and correctly

Visually

locked

Oil level of cable reel gear

Sight glass

Zero emission RTG

Appendixes, section Cable reel

Cleanliness of cable reel gear breather plug or vent hole

Visually

Zero emission RTG

Appendixes, section Cable reel

Oil leaks of cable reel gear

Visually

Zero emission RTG

Noise of cable reel

Audio check

Zero emission RTG

Scheduled maintenance - General General Maintenance procedures to be performed every 500 hours of opera‐ tion: after 500 hours, 1000 hours, 1500 hours, etc. Maintenance manual 308 001 EN

12

C Preventive maintenance – Maintenance tables Maintenance procedures to be performed every 1000 hours of oper‐ ation: after 1000 hours, 2000 hours, 3000 hours, etc. Maintenance procedures to be performed every 2000 hours of oper‐ ation: after 2000 hours, 4000 hours, 6000 hours, etc. Maintenance procedures to be performed every 4000 hours of oper‐ ation: after 4000 hours, 8000 hours, 12000 hours, etc. The daily checks must also be performed during scheduled mainte‐ nance. For reading instructions, see section Reading instructions for main‐

tenance tables.

Maintenance item

Service interval / hours of operation 500

Checking for oil and fluid leaks

1000

2000

4000

x

Lubrication

x

Lubrication must be performed regularly avoiding use of too much lubricant at the same time. (Greasing: e.g. Multipurpose grease, Beacon EP/2). Some greasing points have shorter lubrication intervals.

Service interval / 500 hours of operation Maintenance item

Note



Note

Note



Reference


13


Note

Checking for oil and fluid leaks Lubrication



Note

Checking for oil and fluid leaks Lubrication




14

Scheduled maintenance - Engine Table Maintenance item


Changing oil

1000

2000

Reference

4000

x

Replacing the oil filter(s)

Note

x

Chapter 1, Lubrication

section1.8

Chapter 1, Lubrication

section1.8

Replacing the fuel filter(s)

x

Chapter 1, section 1.2 Fuel

Cleaning the fuel filter(s) (if using Spin- On Type)

x

Chapter 1, section 1.2 Fuel

Empty dust collector of air filter

x

Chapter 1, section 1.6 Air intake/exhaust outlet

Changing coolant filter(s), if in use

x

Chapter 1, section 1.7 Cooling system

system

system

Cleaning breather tube

x


Checking the fan hub bearing clearance

x


Inspection of the damper mounting

x


x

Chapter

vibration

Adjusting valves and injectors

1,section Mechanical parts

Changing air filters (2 pcs) when red indicator flag is at the raised position

x

Steam cleaning of engine

x

Inspection of turbo charger

x

Inspection of idler pulley assembly of the engine

x

Inspection of water pump of the engine

x

Replacing

the

fuel

filter

1.5


Appendixes, section Auxiliary power unit

x

element of auxiliary diesel



Maintenance item


Checking

the

air

induction

1000

2000

Note

the

air

cleaner

x


x


element of auxiliary diesel Checking the external nuts, bolts and unions of auxiliary diesel

Reference

4000

system of auxiliary diesel for leaks, damage and restrictions Replacing

15


x

for tightness

Draining and cleaning the engine mounted fuel tank of

x


x


x


x


x


auxiliary diesel Checking the free movement of the engine and speed controls of auxiliary diesel Cleaning and checking, or replacing, the fuel injector nozzles of auxiliary diesel Replacing the fan drive belt of auxiliary diesel Checking the oil pressure of auxiliary diesel Replacing the oil filter and oil

x

At least once a year.


x



of auxiliary diesel Flushing the cooling system of auxiliary diesel



16


Note

Changing oil Replacing the oil filter(s) Replacing the fuel filter element of auxiliary diesel Checking the air induction system of auxiliary diesel leaks, damage and restrictions

for

Replacing the air cleaner element of auxiliary diesel


Note

Changing oil Replacing the oil filter(s) Replacing the fuel filter(s) Cleaning the fuel filter(s) (if using Spin-On Type) Empty dust collector of air filter Changing coolant filter(s), if in use Replacing the fuel filter element of auxiliary diesel Checking the air induction system of auxiliary diesel leaks, damage and restrictions

for

Replacing the air cleaner element of auxiliary diesel Checking the external nuts, bolts and unions of auxiliary diesel

for tightness




Note

Changing oil Replacing the oil filter(s) Replacing the fuel filter(s) Cleaning fuel filter(s) (if using Spin-On Type) Empty dust collector of air filter Cleaning breather tube Checking the fan hub bearing clearance Inspection of the vibration damper mounting Changing coolant filter(s), if in use Adjusting valves and injectors Replacing the fuel filter element of auxiliary diesel Checking the air induction system of auxiliary diesel leaks, damage and restrictions

for


for tightness

Draining and cleaning the engine mounted fuel tank of auxiliary diesel Checking the free movement of the engine and speed controls of auxiliary diesel Cleaning and checking, or replacing, the fuel injector nozzles of auxiliary diesel Replacing the fan drive belt of auxiliary diesel Checking the oil pressure of auxiliary diesel Replacing the air cleaner element of auxiliary diesel


17


18


Note

Changing oil Replacing the oil filter(s) Replacing the fuel filter(s) Cleaning fuel filter(s) (if using Spin-On Type) Empty dust collector of air filter Cleaning breather tube Checking the fan hub bearing clearance Changing air filters (2 pcs) when red indicator flag is at the raised position Inspection of the vibration damper mounting Changing coolant filter(s), if in use Changing coolant and flushing cooling system Adjusting valves and injectors Steam cleaning of engine Inspection of turbo charger Inspection of idler pulley assembly of the engine Inspection of water pump of the engine Replacing the fuel filter element of auxiliary diesel Checking the air induction system of auxiliary diesel leaks, damage and restrictions

for


for tightness

Draining and cleaning the engine mounted fuel tank of auxiliary diesel Checking the free movement of the engine and speed controls of auxiliary diesel Cleaning and checking, or replacing, the fuel injector nozzles of auxiliary diesel




Note

Replacing the fan drive belt of auxiliary diesel Checking the oil pressure of auxiliary diesel Replacing the air cleaner element of auxiliary diesel Replacing the oil filter and oil of auxiliary diesel


Flushing the cooling system of auxiliary diesel



19

20


Scheduled maintenance - Driveline / Axle Table Maintenance item


Checking the oil level of wheel hubs Lubrication of the cardan shaft and lower bearing

1000

2000

Note

Reference

4000 Chapter 3, section 3.3 Driven

x

wheel and 3.4 Non-driven wheel

Chapter 3, section 3.3 Driven

x

wheel

Adjusting of wheel bearings

x


Lubrication of bearings of the gantry brake motor

x


Checking the tightness of all fixing bolts of mechanical and electrical joints of the gantry brake motor

x

Greasing of bearing housing, vertical axle, pivot axle, steering cylinder and arm, ball head, pinion bearing

wheel

wheel

At least once a year. Chapter 3, section 3.4 Non-driven wheel

x


Changing oil of driven axle assembly, wheel hub planetary gear drive, interaxle differential, wheel bearing

x


x

Chapter 3, section 3.4 Non-driven wheel


Changing oil of non-driven axle assembly





Note

Checking the oil level of wheel hubs


Note

Checking the oil level of wheel hubs


Note

Checking the oil level of wheel hubs Lubrication of the cardan shaft and lower bearing Greasing of bearing housing, vertical axle, pivot axle, steering cylinder and arm, ball head, pinion bearing



21

22



Note

Checking the oil level of wheel hubs Lubrication of the cardan shaft and lower bearing Changing oil of the wheel hubs (driven and non-driven wheels) Adjusting of wheel bearings Changing oil of driven axle assembly, wheel hub planetary gear drive, interaxle differential, wheel bearing


Changing oil of non-driven axle assembly


Greasing of bearing housing, vertical axle, pivot axle, steering cylinder and arm, ball head, pinion bearing


Lubrication of bearings of the gantry brake motor Checking the tightness of all fixing bolts of mechanical and electrical joints of the gantry brake motor




23

Scheduled maintenance - Bakes Table Maintenance item


1000

2000

Note

Reference

Adjust if needed.

Chapter 4, section 4.3. Service

4000

Checking the air gap of the gantry brake

x

Checking alignment

brake

x


Checking the air gap between brake pads and brake disc (brake shoe lift-off) of the hoist brake

x


Checking the lining wear / lining thickness of the hoist brake

x


Checking the condition of the hoist brake disc

x


Checking the reserve stroke of the hoist brake thruster

x


Checking the braking torque of the hoist brake

x


Checking the adjustment of limit switches and manual release devices of the hoist brake

x

Chapter 4, section 4.3. Service brake system

Checking the wear of the automatic wear compensator of the hoist brake

x


Checking the operation of the hoist brake/ brake system

x


the

hoist

brake system

brake system

brake system

brake system

brake system brake system

brake system

brake system

Dynamic hoist brake test

x

Or once a year, whichever comes first.


Static hoist brake test for system with two hoist brakes

x




brake system


24

Maintenance item


1000

2000

Note

Reference

4000

Checking the hoist brake/ brake system outside the regular inspection intervals if: •

•

Prolonged braking times or braking distances appear Extreme operating conditions appear: Overspeeding brake disc.

•

•

•

of

the

And/or excessive braking times. A limit switch indicates lining wear or lack of releasing stroke After a longer period of brake-standstill or drive standstill After hoist emergency stop

Checking the emergency hoist brake hydraulic system for

x

leakages Checking the operating pressure of the emergency

x


x


hoist brake Checking the oil level in the hydraulic unit of the emergency hoist brake Checking visually the condition of the emergency hoist brake

x

Checking the air gap between brake pads and brake disc (release stroke) of the

x


x


emergency hoist brake Checking the lining wear / lining thickness of the emergency hoist brake



Maintenance item


1000

2000

Note

25

Reference

4000

Checking the condition of the emergency hoist brake disc

x


Checking the adjustment of limit switch of the emergency

x


hoist brake Changing oil in the hydraulic unit of the emergency hoist

x


brake Bleeding the emergency hoist

Appendixes, section Emergency hoist brake

x

Appendixes,

x


Emergency hoist brake

brake system

section

Checking the emergency hoist brake/ brake system outside the regular inspection intervals if: •

•

Prolonged braking times or braking distances appear Extreme operating conditions appear: Overspeeding brake disc.

•

•

• •

of

the

And/or excessive braking times. A limit switch indicates lining wear or lack of releasing stroke After a longer period of brake-standstill or drive standstill Any leaks appear After hoist emergency stop

Inspection and maintenance of the skew brake Checking the air gap of the skew brake

x

Adjust if needed.


Checking the air gap of the steering brake

x

Adjust if needed.



brake system

brake system

26

Maintenance item



1000

2000

Note

Reference

4000

Inspection and maintenance of brake of the steering gear brake motor

x

Checking the air gap of the trolley brake

x

Inspection and maintenance of

x


brake system Adjust if needed.

x

trim brake

brake system


the trim brake Checking the air gap of the


If the brake micro switch sends an alarm to the display panel in the cabin, the brake must be checked and possibly adjusted, or the brake pads must be replaced. Brake pad clearance =0.3mm.


brake system

NOTE The micro switch disables the operation of the brakes when the clearance has increased 2.5-fold =0.75mm.

Checking the air gap of the cable reel brake

x

Zero RTG.

emission

Appendixes,

Checking the friction lining medium of the cable reel brake

x

Zero RTG.

emission

Appendixes, section Emergency hoist brake

Checking the torque of the cable reel brake

x

Zero RTG.

emission

Appendixes,




section

section



Note

Checking the emergency hoist brake hydraulic system for leakages Checking the operating pressure of the emergency hoist brake Checking the oil level in the hydraulic unit of the emergency hoist brake


27

28



Note


Adjust if needed.

Checking the hoist brake alignment Checking the air gap between brake pads and brake disc (brake shoe lift-off) of the hoist brake Checking the lining wear / lining thickness of the hoist brake Checking the condition of the hoist brake disc Checking the reserve stroke of the hoist brake thruster Checking the braking torque of the hoist brake Checking the adjustment of limit switches and manual release devices of the hoist brake Checking the wear of the automatic wear compensator of the hoist brake Checking the operation of the hoist brake / brake system Checking the emergency hoist brake hydraulic system for leakages Checking the operating pressure of the emergency hoist brake Checking the oil level in the hydraulic unit of the emergency hoist brake Checking visually the condition of the emergency hoist brake Checking the air gap between brake pads and brake disc (release stroke) of the emergency hoist brake Checking the lining wear / lining thickness of the emergency hoist brake Checking the condition of the emergency hoist brake disc

Checking the adjustment of limit switch of the emergency hoist brake Checking the air gap of the cable reel brake

Zero emission RTG


Zero emission RTG




Note


Zero emission RTG


29

30



Note


Adjust if needed.

Checking the hoist brake alignment Checking the air gap between brake pads and brake disc (brake shoe lift-off) of the hoist brake Checking the lining wear / lining thickness of the hoist brake Checking the condition of the hoist brake disc Checking the reserve stroke of the hoist brake thruster Checking the braking torque of the hoist brake Checking the adjustment of limit switches and manual release devices of the hoist brake Checking the wear of the automatic wear compensator of the hoist brake Checking the operation of the hoist brake / brake system Checking the emergency hoist brake hydraulic system for leakages Checking the operating pressure of the emergency hoist brake Checking the oil level in the hydraulic unit of the emergency hoist brake Checking visually the condition of the emergency hoist brake Checking the air gap between brake pads and brake disc (release stroke) of the emergency hoist brake Checking the lining wear / lining thickness of the emergency hoist brake Checking the condition of the emergency hoist brake disc

Checking the adjustment of limit switch of the emergency hoist brake Changing oil in the hydraulic unit of the emergency hoist brake




Note

Bleeding the emergency hoist brake system Inspection and maintenance of the skew brake Checking the air gap of the cable reel brake

Zero emission RTG


Zero emission RTG


Zero emission RTG


31

32



Note


Adjust if needed.

Checking the hoist brake alignment Checking the air gap between brake pads and brake disc (brake shoe lift-off) of the hoist brake Checking the lining wear / lining thickness of the hoist brake Checking the condition of the hoist brake disc Checking the reserve stroke of the hoist brake thruster Checking the braking torque of the hoist brake Checking the adjustment of limit switches and manual release devices of the hoist brake Checking the wear of the automatic wear compensator of the hoist brake Checking the operation of the hoist brake / brake system Dynamic hoist brake test Static hoist brake test for system with two hoist brakes Checking the emergency hoist brake hydraulic system for leakages Checking the operating pressure of the emergency hoist brake Checking the oil level in the hydraulic unit of the emergency hoist brake Checking visually the condition of the emergency hoist brake Checking the air gap between brake pads and brake disc (release stroke) of the emergency hoist brake Checking the lining wear / lining thickness of the emergency hoist brake Checking the condition of the emergency hoist brake disc

Checking the adjustment of limit switch of the emergency hoist brake




Note

Changing oil in the hydraulic unit of the emergency hoist brake Bleeding the emergency hoist brake system Inspection and maintenance of the skew brake Checking the air gap of the skew brake

Adjust if needed.

Checking the air gap of the steering brake

Adjust if needed.

Inspection and maintenance of brake of the steering gear brake motor Checking the air gap of the trolley brake

Adjust if needed.

Inspection and maintenance of the trim brake


33


34

Scheduled maintenance - Steering Table Maintenance item


1000

2000

Checking during operation of the gantry brake motor that running smoothness of machine and running noise of bearings have not deteriorated

x

Checking during standstill that no subsidence or cracks have occurred in the foundation of the gantry brake motor

x

Note

Reference

4000

Checking steering gear for leakage

x

Chapter 5, section 5.2 Power assisted system

Checking oil level of steering gear

x


Changing oil of the steering gear

x


Cleaning housing

gear

x

Cleaning of breather plug of steering gear

x

Checking fixing screws for tightness of the steering gear brake motor

x

of

steering


Note

Checking during operation of the gantry brake motor that running smoothness of machine and running noise of bearings have not deteriorated Checking during standstill that no subsidence or cracks have occurred in the foundation of the gantry brake motor





35


Note

Checking during operation of the gantry brake motor that running smoothness of machine and running noise of bearings have not deteriorated Checking during standstill that no subsidence or cracks have occurred in the foundation of the gantry brake motor Checking steering gear for leakage Checking oil level of steering gear Changing oil of the steering gear Cleaning of steering gear housing Cleaning of breather plug of steering gear Checking fixing screws for tightness of the steering gear brake motor


Scheduled maintenance - Suspension Table Maintenance item


Checking the wheel tightening torque

nuts

1000

2000

Note

4000 Chapter 6, section 6.3 Tyres

x

Checking the condition of the outer shell of wheel rim

and rims

x


Note

Checking the wheel nuts tightening torque


Reference

Note




36



Note



Note

Checking the wheel nuts tightening torque Checking the condition of the outer shell of wheel rim




37

Scheduled maintenance - Load handling Table Maintenance item


1000

Cleaning vent plug of trolley gear

x

Lubricating gear

trolley

x

Cleaning grease nipples of trolley gear

x

seals

of

2000

Checking trolley gear unit for leakage

x

Checking the tightness of fixing screws of cardan shaft of the trolley gear

x

x

Cleaning housing

x

Lubrication of trolley motor

trolley

gear

bearings

of

Cleaning the breather plug of the hoist gear

the

hoist

x

x

gear

x

Checking fixing screws for tightness of the connection between the hoist gear and drum.

x

Lubrication of seals and cleaning of grease nipples of the hoist gear

Chapter 7, section 7.4 Side movement

Chapter 7, section 7.2 Lifting/ lowering

x

Changing oil of hoist gear

Cleaning housing

Reference

4000

Changing oil of trolley gear

the

Note



x



38

Maintenance item


1000

2000

Checking during operation of the hoist motor that specified technical data are met (power input, temperatures of windings, bearings, coolants, etc.)

x

Checking during operation of the hoist motor that running smoothness of machine and running noise of bearings have not deteriorated

x

Checking during standstill of the hoist motor that no subsidence or cracks have occurred in the foundation

x

Note

Reference

4000

Lubricating the bearings of hoist motor

x

Checking the tightness of fixing bolts of mechanical and electrical joints of hoist motor

x

Checking the alignment hoist machinery

of

x

Checking the hoist motor's insulation resistance of windings is satisfactory

x

Checking that no bearing insulation is short-circuited in the hoist motor

x

Checking the hoist motor's cables and insulating parts (as far as accessible) are in proper condition and show no signs of discolouration

x


Chapter 7, section 7.2 Lifting/

lowering



Maintenance item


1000

Greasing the hoist ropes

x

Checking the ropes at full length paying special attention to the following: terminal points; section that goes over the pulley; section straight above the balancing wheel.

x

2000

Reference

4000 Depending on climatic conditions, rope lubrication interval may be extended to 2 months. Spread mineral oil (Engine oil 10W/ Diesel oil CD10W) with a brush.

Checking during operation of the trolley motor that running smoothness of machine and running noise of bearings have not deteriorated

x

Checking during standstill that no subsidence or cracks have occurred in the foundation of the trolley motor

x

Checking the tightness of fixing bolts of mechanical and electrical joints of the trolley motor

x

Tightening of the most important screws and bolts

Chapter 7, section 7.2 Lifting/

x

lowering

Checking the oil level of the skew gear

x

Changing oil of the skew gear

x

Checking the skew gear for leakage

x

Lubrication of the skew geared brake motor

Note

39

Chapter 7, section 7.4 Side movement At least every 6 years.

Chapter 7, section 7.4 Side movement Chapter 7, section 7.4 Side

movement


x



40

Maintenance item


1000

2000

Note

4000

Checking fixing screws for tightness of skew geared brake motor

x


Checking the condition of bearings of skew geared brake motor

x

Change bearings every 6 years if needed. When change the bearings, need full oil.

Checking the length of chain of skew

x

Cleaning housing

gear

x

Cleaning the breather plug of the skew gear

x

Checking the trim gear for

x

the

skew



leakage Checking the operation of trim

x

gear Checking the oil level of trim

At least once a year. Chapter 7, section 7.2 Lifting/ lowering

x

gear Lubrication of the trim geared

Reference


x

brake motor x


of

x


of

x

Cleaning the trim gear housing

x

Cleaning the breather plug of

x

Changing oil of trim gear Checking

the

operation

sensors for trim turning Checking

the

tightness

fixing screws of trim device



trim gear Checking the condition of the glide plates of spreader

x




Maintenance item


1000

2000

41

Note

Reference

4000

Replacing the pins and spherical washers of the twistlocks of spreader

x


Checking the gears of the telescoping system of spreader

x


Inspection of the twistlocks of headblock using liquid penetrant or magnetic particle examination

x

After lifting 400,000 tanks, replace the headblock twistlocks.


Checking the spreader's twistlock nut and the floating mechanism and ensure that all parts are properly tightened down

x



Checking that the spreader's twistlock pin can be moved easily and it indicates the correct position

x



Lubrication of spreader

x


Dismantle, inspect and perform crack detection of the spreader

x

Replacing the glide plates of the spreader

x

Minimum thickness mm.

Checking the chain elongation of the spreader

x

Renew chain and gears when max trimming allowance is achieved.

Checking the pressure in the

nitrogen spreader's


17



x

Appendixes, section Spreader hydraulic unit

x


hydraulic accumulators Adjustment of pressure in the spreader's hydraulic system



42

Maintenance item


1000

2000

Note

Reference

4000

Changing hydraulic oil of spreader's hydraulic system

x


Cleaning

x


the

housing

of

spreader's hydraulic unit Changing the return filter(s) of

x


x


x


x


spreader's hydraulic unit Changing the pressure filter(s) of spreader's hydraulic unit Changing the air filter(s) of spreader's hydraulic unit Cleaning the breather plug of spreader's hydraulic unit Checking the trolley frame weldings

x




43


Note

Cleaning vent plug of trolley gear Lubricating seals of trolley gear Cleaning grease nipples of trolley gear Lubrication of the skew geared brake motor Cleaning the breather plug of the hoist gear Greasing the hoist ropes

Depending on climatic conditions, rope lubrication interval may be extended to 2 months. Spread mineral oil (Engine oil 10W / Diesel oil CD10W) with a brush.

Checking the ropes at full length paying special attention to the following: terminal points; section that goes over the pulley; section straight above the balancing wheel. Checking the condition of the glide plates of spreader Lubrication of spreader Changing the return filter(s) of spreader's hydraulic unit Changing the pressure filter(s) of spreader's hydraulic unit

Changing the air filter(s) of spreader's hydraulic unit Cleaning the breather plug of spreader's hydraulic unit


44



Note

Checking trolley gear unit for leakage Cleaning vent plug of trolley gear Lubricating seals of trolley gear Cleaning grease nipples of trolley gear Lubrication of the skew geared brake motor Lubrication of bearings of trolley motor Checking during operation of the trolley motor that running smoothness of machine and running noise of bearings have not deteriorated Checking during standstill that no subsidence or cracks have occurred in the foundation of the trolley motor Cleaning the breather plug of the hoist gear Lubrication of seals and cleaning of grease nipples of the hoist gear Greasing the hoist ropes


Checking the ropes at full length paying special attention to the following: terminal points; section that goes over the pulley; section straight above the balancing wheel. Checking the tightness of fixing screws of cardan shaft of the trolley gear Lubrication of the trim geared brake motor Checking during operation of the hoist motor that specified technical data are met (power input, temperatures of windings, bearings, coolants, etc.) Checking during operation of the hoist motor that running smoothness of machine and running noise of bearings have not deteriorated Checking during standstill of the hoist motor that no subsidence or cracks have occurred in the foundation Lubrication of spreader Dismantle, inspect and perform crack detection of the spreader



45


Note

Replacing the glide plates of the spreader

Minimum thickness 17mm.

Checking the chain elongation of the spreader


Tightening of the most important screws and bolts Changing the return filter(s) of spreader's hydraulic unit Changing the pressure filter(s) of spreader's hydraulic unit

Changing the air filter(s) of spreader's hydraulic unit Cleaning the breather plug of spreader's hydraulic unit


46



Note

Checking trolley gear for leakage Cleaning vent plug of trolley gear Lubricating seals of trolley gear Cleaning grease nipples of trolley gear Changing oil of trolley gear Cleaning the trolley gear housing Lubrication of bearings of trolley motor Lubrication of the skew geared brake motor Checking the oil level of the skew gear Changing oil of the skew gear

At least every 6 years.

Checking the skew gear for leakage Checking fixing screws for tightness of skew geared brake motor


Checking the condition of bearings of skew geared brake motor

Change bearings every 6 years if needed. When change the bearings, need full oil.

Checking the length of chain of skew Cleaning the skew gear housing Cleaning the breather plug of the skew gear Lubricating the bearings of hoist motor Checking the alignment of hoist machinery Checking the tightness of fixing bolts of mechanical and electrical joints of hoist motor Checking that the hoist motor's insulation resistance of windings is satisfactory Checking that no bearing insulation is short-circuited in the hoist motor Checking the hoist motor's cables and insulating parts (as far as accessible) are in proper condition and show no signs of discolouration



47


Note

Checking during operation of the hoist motor that specified technical data are met (power input, temperatures of windings, bearings, coolants, etc.) Checking during operation of the hoist motor that running smoothness of machine and running noise of bearings have not deteriorated Checking during standstill of the hoist motor that no subsidence or cracks have occurred in the foundation Checking during operation of the trolley motor that running smoothness of machine and running noise of bearings have not deteriorated Checking during standstill that no subsidence or cracks have occurred in the foundation of the trolley motor Checking the tightness of fixing bolts of mechanical and electrical joints of the trolley motor Lubrication of seals and cleaning the grease nipples of the hoist gear Changing oil of hoist gear Cleaning the hoist gear housing Checking fixing screws for tightness of hoist gear Cleaning the breather plug of the hoist gear Greasing the hoist ropes


Checking the ropes at full length paying special attention to the following: terminal points; section that goes over the pulley; section straight above the balancing wheel. Checking the tightness of fixing screws of cardan shaft of trolley gear Checking the trim gear for leakage Checking the operation of trim gear


Checking the oil level of trim gear Changing oil of trim gear



48


Note

Checking the operation of sensors for trim turning At least once a year.

Checking the tightness of fixing screws of trim device Lubrication of the trim geared brake motor Cleaning the trim gear housing Cleaning the breather plug of trim gear Lubrication of spreader Dismantle, inspect and perform crack detection of the spreader Checking the condition of the glide plates of spreader Replacing the glide plates of the spreader Checking the chain elongation of the spreader


Replacing the pins and spherical washers of the twistlocks of spreader Checking the gears of the telescoping system of spreader Inspection of the twistlocks of headblock using liquid penetrant or magnetic particle examination

After lifting 400,000 tanks, replace the headblock twistlocks.

Checking the spreader's twistlock nut and the floating mechanism and ensure that all parts are properly tightened down


Checking that the spreader's twistlock pin can be moved easily and it indicates the correct position


Calibrate load cells

At least once a year or after changing the ropes.

using the touch panel (if E-One2).

Changing the return filter(s) of spreader's hydraulic unit Changing the pressure filter(s) of spreader's hydraulic unit

Changing the air filter(s) of spreader's hydraulic unit Cleaning the breather plug of spreader's hydraulic unit Checking the nitrogen pressure in the spreader's hydraulic accumulators




Note

Adjustment of pressure in the spreader's hydraulic system

Changing hydraulic oil of spreader's hydraulic system Cleaning the housing of spreader's hydraulic unit Tightening of the most important screws and bolts Checking the trolley frame weldings



49


50

Scheduled maintenance - Frame, body, cab and accessories Table Maintenance item


Cleaning and checking the condition of the anemometer

1000

2000

Note

Reference

Cleaning and inspection should be done every 500 hours or depending on climate conditions every three months.

Chapter 9, section 9.2 Safety and emergency equipment

Chapter 9, section 9.12 Frame

4000

x

Checking all weldings of the main crossbeams from the centre to distance of 3.5m including run rails

x


Checking the weldings of the flange of the pivot arm

x


Checking the weldings of the lower end of the vertical column to height of 3 m from the sill beam

x



x

At least once in 6 months.

Section 9, chapter 9.12 Frame

x









Every 3000 hours of operation, at least once a year.


Checking the mounting of the power unit Checking the tightness of fixing bolts of stairs and ladders Checking the safety wire of the cabin Checking the mounting of the cabin Checking and tighten the bolt and screw connections

x

x

x

Checking tightness and condition of frame joint bolts



Maintenance item


Checking PLC driver’s cabin

wiring

1000

2000

in

Note

51

Reference

4000 x

PLC wiring’s fastening should be checked twice a year from the hole under the seat. Seat can be tilted by opening locking bolts at the front of the base of the seat.

Cleaning the machine exterior thoroughly with pressure washer to remove dust, salt and other impurities from the structures.


Inspecting visually the paint condition for cracks, rust and other damages. Inspection is carried out for all painted surfaces on the crane. Damaged paint must be immediately repaired by properly cleaning and repair painting the area according to instructions in document TO4158.

At least once in 6 months. After every accident.

Appendixes, section Touch-up repair painting


Appendixes,

section

Air

Check and clean the drain trays of the cabin and EEhouse air condition units.

x

conditioning unit

Clean the air filters of the cabin and EE-house air condition units.

x


Appendixes,

section

Air

Clean the unit casings of the cabin and EE-house air condition units.

x


Appendixes,

section

Air

conditioning unit

conditioning unit


Note




52



Note



Checking the safety wire of the cabin


Check and clean the drain trays of the cabin and EE-house air condition units.



Note







Checking the mounting of the power unit


Checking the tightness of fixing bolts of stairs and ladders


Checking the mounting of the cabin




53


Note







Checking the mounting of the power unit






Checking all weldings of the main crossbeams from the centre to distance of 3.5m including run rails


Checking the weldings of the flange of the pivot arm


Checking the weldings of the lower end of the vertical column to height of 3 m from the sill beam


Checking and tighten the bolt and screw connections


Checking PLC wiring in driver’s cabin

PLC wiring’s fastening should be checked twice a year from the hole under the seat. Seat can be tilted by opening locking bolts at the front of the base of the seat.

Clean the air filters of the cabin and EE-house air condition units.


Clean the unit casings of the cabin and EE-house air condition units.




54

Scheduled maintenance - Common electrics Table Maintenance item


Checking the condition starting batteries

of

x

Checking the condition of starting batteries of auxiliary

x

1000

2000

Note

Reference

4000

diesel of

x

Section 11, chapter Distribution of electricity

11.5

Checking the strain reliefs of

x


11.5

x


11.5

Checking the energy chain for obstructions

x


11.5

Checking the condition of roller

x


11.5

x


11.5

of

x


11.5

Checking the operation of moving arm of energy chain

x


11.5

Checking

the

condition

endpoints of energy chain

energy chain Checking the wear of energy chain

links of energy chain Checking the condition of cables and hoses of energy chain Checking

the

condition

troughs of energy chain



Maintenance item


Checking and cleaning cable reel slip ring bodies: • •

•

•

•

•

•

1000

2000

Note

55

Reference

4000

x

Zero RTG.

emission

Basic cleaning of the complete slip ring body. Removal for humidity and dust from the insulator surfaces with a soft cloth or a pencil. Examination of the insulators as to damage or replacement. Examination or cleaning of the ring sliding surfaces on which the current collectors are running. Removal of enamel beads, arcing spots or oxidationen. Inspection of the current collectors for wear or replacement. Control of the fixing and connecting screws for tight fit.

Appendixes, reel

section

Cable

NOTE Danger of electric shock. See section B Safety, chapter Electric systems for safety instructions.

Cleaning of the ring sliding surfaces can be made with a very fine abrasive paper. Changing oil of the cable reel gear

Zero emission RTG. 10 000 hours of operation or every 3 years, whichever comes first.

Appendixes,

section

Cable

Replacing lubricating grease of the cable reel motor

Zero emission RTG. 20 000 hours of operation.

Appendixes,

section

Cable

Checking temperature of the cable reel gear bearings and oil sump (max. 80°C)

x

Zero RTG.

emission

Checking visually the cable reel gear lubricating oil for water content

x

Zero RTG.

emission


reel

reel


56

Maintenance item


1000

2000

Note

Reference

4000

Checking the cable reel drive gear for extraordinary noise

x

Zero RTG.

emission

Checking the breather of the cable reel gear for cleanliness

x

Zero RTG.

emission

Checking the cable reel gear for oil leaks, small oil leak from the output shaft is acceptable

x

Zero RTG.

emission

Checking condition power supply cable

x

Zero RTG.

emission

of

the


Note

Checking the condition of starting batteries Checking the condition of starting batteries of auxiliary diesel Checking the condition of endpoints of energy chain Checking the strain reliefs of energy chain




Note

Checking the condition of starting batteries Checking the endpoints of energy chain Checking the strain reliefs of energy chain Checking and cleaning cable reel slip ring bodies: • • • • • • •

Zero emission RTG



Cleaning of the ring sliding surfaces can be made with a very fine abrasive paper. Checking temperature of the cable reel gear at bearings and oil sump (max. 80°C)

Zero emission RTG


Zero emission RTG


Zero emission RTG


Zero emission RTG


Zero emission RTG

Checking condition of the power supply cable

Zero emission RTG


57


58


Note

Checking the condition of starting batteries Checking the condition of the endpoints of energy chain Checking the condition of the strain reliefs of energy chain

Checking the wear of energy chain Checking the energy

chain for obstructions

Checking the condition of roller links of energy chain Checking the condition of cables and hoses of energy chain Checking the condition of troughs of energy chain Checking the operation of moving arm of energy chain Checking and cleaning cable reel slip ring bodies: • • • • • • •

Zero emission RTG




Zero emission RTG


Zero emission RTG


Zero emission RTG


Zero emission RTG


Zero emission RTG


Zero emission RTG




Note

Checking the condition of starting batteries Checking the endpoints of energy chain Checking the strain reliefs of energy chain Checking the wear of energy chain Checking the energy

chain for obstructions

Checking the roller links of energy chain Checking the cables of energy chain Checking the troughs of energy chain Checking the moving arm of energy chain Check functionality of the residual current devices (RCD) by pressing the test buttons. Checking and cleaning cable reel slip ring bodies: • • • • • • •

Zero emission RTG




Zero emission RTG


Zero emission RTG


Zero emission RTG


Zero emission RTG


59

60



Note


Zero emission RTG


Zero emission RTG

Scheduled maintenance - Technical data Table Maintenance item


Tighten mounting bolts

1000

2000

Chapter F Technical data

x

Note



Note



Reference

4000


Note

Note



1

Table of content 0 Complete machine

3


2


0 Complete machine – Troubleshooting without error code

0

3

Complete machine

Troubleshooting, general work instructions When troubleshooting, it is important to work in a structured and logical manner. The person doing the troubleshooting must be very familiar with the operation of the machine and its main components. In order to be able to locate any malfunctions in the steering and other systems, the person must be able to read the machine circuit diagrams in a professional manner. Follow the troubleshooting sequence indicated in the maintenance manual to ensure that the condition of the components and systems is checked systematically and any malfunctions are located without delay. When troubleshooting, it is important to understand how the machine functions, as certain malfunctions can be identified directly using function descriptions. The functions of the machine are descri‐ bed in chapters 1 Engine - 9 Frame.

Troubleshooting 1. 2.

3. 4. 5.

Check that there is battery voltage available. Check that the fuses are intact. • Check that all oil and fluid levels are normal. Fuel • Engine • Gears • Hubs • • Hydraulic, spreader Coolant • Check the error codes on the display. If error codes are displayed, refer to the error code list. See Troubleshooting with error code. If no error codes are displayed, check the appropriate function description in Chapters 1–9. See Troubleshooting without error code .

Troubleshooting without error code The function descriptions contain information about the components that are involved in the function and how these components work together. In certain cases, there is information about which condi‐ tions apply to enable activation of the function.


4

0 Complete machine – Troubleshooting with error code

1. 2.

3.

4.

5.

6.

Select the appropriate section, 1-9. Read the description of the function in question to get an over‐ all understanding of which components are affected and how these interact. Use the function description and check the signals for the func‐ tion to find where in the function chain that signal or reaction is incorrect. The malfunction is probably between the two units where the signal is incorrect. Start by checking the component that should send the signal. If the component that should send the signal is intact, check the transmission of the signal in the cables or hydraulic hoses. For more information about cables, see Troubleshooting cables . If cables or hoses between components seem to be intact, check the component receiving the signal.

Troubleshooting with error code 1. 2. 3.

4.

Read the message on the display. Check the details from the error code list. Use the function group to find more information if needed. Sections 1–9 provide function descriptions and descriptions of components, their positions, and in certain cases work instruc‐ tions for checking and adjusting components. If possible, exclude component malfunction by testing the sus‐ pected component separately. Electric components can usually be checked by resistance measurements using a multimeter.

5.

Hydraulic components are most often checked by measuring pressure; in such cases, this is described in the function group or in connection with preventive maintenance. If the component’s measurement values are correct, continue by troubleshooting the hydraulic hoses and cables. See Trou‐ bleshooting cables .

Troubleshooting cables

DANGER Risk of electric shock! Before commencing work, ensure that the electric system is de-ener‐ gised.

NOTE Troubleshoot all cables in the same way to prevent damaging the con‐ trol units, components, or measuring instruments.


0 Complete machine – Troubleshooting cables

1. 2. 3.

5

For de-energising the electric system, see Chapter B Safety, section Electric systems. Refer to the appropriate circuit diagram, check the connections and any joints of the suspected cable. Check the cable as follows: a) Disconnect the connector from both the control unit and component. b) Connect the other end of the cable to a point on the frame structure where the cable touches the metal surface with‐ out a film of paint or coating. c) Use a multimeter to measure the cable resistance between the cable and the machine frame. d) The cable is intact if the multimeter shows constant resist‐ ance.


6

0 Complete machine – Troubleshooting cables


1

Table of content 1 Cummins

3

1.2 Fuel system 1.2.1 Removing water from the water separator

3 4

1.2.2 Replacing the fuel prefilter

4

1.2.3 Replacing the fuel filter

5

1.2.4 Bleeding the fuel system

6

1.2.5 Cleaning the fuel tank

7

1.5 Mechanical parts 1.5.1 Adjusting the valve clearances and unit injector rocker arms 1.6 Air intake / exhaust outlet 1.6.1 Checking the air filter indicator

8 8 14 15

1.6.2 Replacing the air filter

15

1.6.3 Empty dust collector of air filter

16

1.6.4 Clean and check the crankcase breather tube

16

1.6.5 Check the vibration damper

16

1.6.6 Check the fan hub bearing clearance

17

1.7 Cooling system 1.7.1 Checking the coolant level

18 19

1.7.2 Changing the coolant filter

19

1.7.3 Changing the coolant and flushing the cooling system

20

1.7.4 External cleaning of the radiator

21

1.8 Lubrication system 1.8.1 Checking the oil level

22 24

1.8.2 Replacing the oil filter

25

1.8.3 Changing oil

26


2


1 Cummins – 1.2 Fuel system

1

Cummins

1.2

Fuel system

3

Description Fuel is transferred from the fuel tank by a feed pump. The feed pump starts when the main power is switched on. The fuel flows to the engine fuel pump through filters. Overflow from the engine returns to the tank.

Component position

Fig. : Flow diagram, Fuel system 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Fuel supply from tank Fuel filter Gear pump Fuel shut-off valve Rail metering actuator Timing actuator Rail metering supply to actuator Timing fuel supply to injector Injector Fuel drain to tank


4


1.2.1

Removing water from the water separator

Instructions

CAUTION The fuel is highly flammable. Do not smoke or use an open flame when handling the fuel. Avoid skin contact with the fuel. Use protective gloves.

IMPORTANT Be careful not to discharge fuel into the environment. Use an appro‐ priate container, and deliver the fuel to a hazardous waste collection point. 1 2

3

Place the fuel container below the filter. Loose the drain valve nut completely so that the valve drops down from the filter about 25 mm (1 inch). Drain the water and the sediment out. Retighten the drain valve nut when clean fuel is draining out.

1.2.2

Replacing the fuel prefilter

Instructions




5

IMPORTANT Be careful not to discharge fuel into the environment. Use an appro‐ priate container, and deliver the fuel and the used filter to a hazard‐ ous waste collection point. Ensure absolute cleanliness. Impurities in fuel cause damage to the system. 1 2 3 4 5

Place the fuel container below the filter. Clean the filter and the area around it. Open the valve at the bottom, and drain the fluid from the filter into the container. Remove the filter, and move the water separator to the new filter. Tighten the new filter into place by hand.

NOTE Do not use a tool for tightening to prevent damage to the filter. 6

Start the engine, and check the filter for leaks.

1.2.3

Replacing the fuel filter

Instructions


IMPORTANT Be careful not to discharge fuel into the environment. Use an appro‐ priate container, and deliver the fuel to a hazardous waste collection point. Take care to ensure absolute cleanliness. Impurities in fuel cause damage to the system.


6

1 Cummins – 1.2 Fuel system 1 2 3

Place the fuel container below the filter. Clean the filter and the area around it. Remove the filter element.

NOTE Fill the new filter with clean fuel prior to installation. 4 5

6 7

Apply a thin film of clean engine oil to the filter gasket sealing surface. Install the filter onto the filter head. Turn the filter until the gas‐ ket contacts the filterhead surface. Tighten the filter an adi‐ tional 3/4 of a turn. Bleed the fuel system; see 1.2.4 Bleeding the fuel system. Start the engine, and check the filter for leaks.

1.2.4

Bleeding the fuel system

General The fuel system is bled using the pressure generated by the feed pump, which is used to move fuel from the fuel tank. Instructions


IMPORTANT Be careful not to discharge fuel into the environment. Use an appro‐ priate container, and deliver the fuel to a hazardous waste collection point.


1 Cummins – 1.2 Fuel system 1 2

1

3 4 5 6

7

Push the button (1) down on the integrated fuel system mod‐ ule. Crank the engine until a solid stream of fuel comes out of the port. Release the button (1). Crank the engine for 20 seconds. If the engine does not start within 20 seconds, wait 2 minutes. Repeat these steps until the engine starts. Start the engine. After the engine has started, close the valve. If the engine does not start after bleeding, bleed the system again.

1.2.5

Cleaning the fuel tank

Instructions


IMPORTANT Be careful not to discharge fuel into the environment. Use an appro‐ priate container, and deliver the fuel to a hazardous waste collection point. 1 2 3

Drain the fuel tank into the container through the drain valve. Rinse the tank with clean fuel. Close the valve, and fill the tank.


8

1 Cummins – 1.5 Mechanical parts

1.5

Mechanical parts

1.5.1

Adjusting the valve clearances and unit injector rocker arms

General The adjustments are to be performed when the engine is cold. Let the engine cool down for at least 30 minutes after use.

WARNING Batteries can emit explosive gases. To avoid personal injury, always ventilate the compartment before servicing the batteries. To avoid aching, remove the negative (-) battery cable first and attach the neg‐ ative (-) battery last. Disconnect the battery.

NOTE Read the entire procedure for overhead adjustment before attempting to perform this operation. Valves, injectors, and engine brake (if equipped) must be correctly adjusted for the engine to operate efficiently. Valve, injector, and engine brake adjustment must be performed using the values listed in this section. Adjust the valves, injectors, and engine brakes every 3,000 hours. Adjustment should be made after any major repair. After a major repair, the adjustment interval again becomes every 3000 hours. Adjust All overhead valve, injector, and brake adjustments must be made when the engine is cold (any stabilized coolant temperature at 60°C [140°F] or below).

CAUTION Do not use solvent to clean the rocker cover gasket. Solvent can damage the gasket material and cause it to swell. Locate the valve set marks on the outside of the vibration damper. The set marks are A, B, and C: • • •

Set to mark A to adjust cylinders 1 or 6. Set to mark B to adjust cylinders 2 or 5. Set to mark C to adjust cylinders 3 or 4.



9

NOTE Two complete revolutions are required to set all valves and injectors.

WARNING Do not straighten a bent fan blade or continue to use a damaged fan. A bent or damaged fan blade can fail during operation and cause per‐ sonal injury or property damage. The crankshaft rotation is clockwise as viewed from the front of the engine. The cylinders are numbered from the front of the engine (1-2-3-4-5-6). The engine firing order is 1-5-3-6-2-4. Barring Device

Remove one capscrew and loosen the second capscrew, then rotate cover.


10

1 Cummins – 1.5 Mechanical parts Use a 1-112-inch socket, and bar engine over counterclockwise.

NOTE Rock the barring device back and forth until it disengages.

Each cylinder has four rocker levers: • • • •

The exhaust valve rocker lever (1) The injector rocker lever (2) The intake valve rocker lever (3) The engine brake rocker lever (4).

The valves and the injectors on the same cylinder are adjusted at the same index mark on the vibration damper.

QSX15 Injector and valve adjustment sequence Bar engine in direction of rotation

Pulley position

Set cylinder injector

Set cylinder

Start

A

1

1

Advanced to

B

5

5

Advanced to

C

3

3

Advanced to

A

6

6

Advanced to

B

2

2

Advanced to

C

4

4

Firing order: I-5-3-6-2-4 Rotate the air compressor drive in the direction of engine rotation, clockwise. Align the A mark on the vibration damper with the pointer on the gear cover.

NOTE For illustrative purposes, position A is shown as the first step. It is not necessary to start with position A, as long as the proper sequence is followed.



11

Check the valve rocker levers on the given cylinder to see if both exhaust valves are closed.

NOTE Both valves are closed when both rocker levers are loose. If both valves are not closed, rotate the compressor drive gear one complete revolution, and align the A mark on the front damper with the pointer again.

Loosen the injector adjusting screw locknut on the cylinder. Use a dial-type torque wrench, Part No. 3375044 with a range of 0 to 150 in-Ib to tighten the injector rocker lever adjusting screw. If the screw chatters during setting. Repair the screw and lever as required.

NOTE Do not use a click-type torque wrench. Back out the adjusting screw one or two turns. Back out the adjusting screw one or two turns. Hold the torque wrench in a position that allows you to look in a direct line at the dial. This is to make sure the dial with be read accurately. Make sure the parts are aligned, and squeeze the oil out of the valve and injector train by tightening the adjusting screw.

NOTE Use this initial adjustment to preload the valve train and injector. Tighten the injector adjusting screw. Torque Value: 8 N•m [70 in-Ib] Tighten the injector lever adjusting screw. Torque Value: 8 N•m [70 in-Ib]


12

1 Cummins – 1.5 Mechanical parts Hold the injector lever adjusting screw, and tighten the adjusting screw locknut. Torque Value: 75 N•m [55 ft-Ib]

After setting the injector on a cylinder, set the valves on the same cylinder.

With the set mark aligned with the pointer on the gear cover and both valves closed on the cylinder, loosen the locknuts on the intake and exhaust valve adjusting screws. Back out the adjusting screw one or two turns.

Select a feeler gauge for the correct valve lash specification.

Valve Lash Specifications Intake

Exhaust

0.36 mm

0.69 mm

[0.014 in]

[0.027 in]

Insert the feeler gauge between the top of the crosshead and the rocker lever nose pad.



13

Tighten the adjusting screw. Torque Value: 0.6 N•m [5 in-Ib]

NOTE Use torque wrench adapter, Part No. 3375044, to tighten the locknut. Hold the adjusting screw in this position. The adjusting screw must not turn when the locknut is tightened. Torque Value: 45 N•m [33 ft-IbJ

After tightening the locknut to the correct torque value, remove the feeler gauge. Repeat the process to adjust all injectors and valves according to the chart shown earlier in this procedure.

QSX15 Injector and valve adjustment sequence Bar engine in direction of rotation

Pulley position

Set cylinder injector

Set cylinder

Start

A

1

1

Advanced to

B

5

5

Advanced to

C

3

3

Advanced to

A

6

6

Advanced to

B

2

2

Advanced to

C

4

4

Firing order: I-5-3-6-2-4


1 Cummins – 1.6 Air intake / exhaust outlet

14

1.6

Air intake / exhaust outlet

Component position, air intake system 6

2

5

4 4

1 3

1. 2. 3. 4. 5. 6.

Intake air inlet to turbocharger Turbocharger to air to charge air cooler Charge air cooler From charge air cooler to intake manifold Intake valve ports Intake valves

Component position, exhaust system 1. 2. 3.

2

Exhaust valve ports Exhaust manifold Turbocharger turbine

1

3



1.6.1

15

Checking the air filter indicator

Instructions

1

The air filter is replaced during scheduled maintenance. Depending on conditions, the air filter may clog during a relatively short operat‐ ing period. The air filter is equipped with a clog warning indicator (1). Check the indicator regularly. The filter must always be replaced if the clog warning indicator shows completely red.

1.6.2

Replacing the air filter

Instructions 1 2 3

4 5

Open the filter housing cover. Remove the air filter (the larger filter element). Check the safety cartridge (the smaller filter element); replace if necessary. The safety cartridge is usually replaced every other time the air filter is replaced. Install the new air filter, and mount the cover. Reset the clog warning indicator by pressing the button on its end.


16


1.6.3

Empty dust collector of air filter

Instructions Empty dust collector of air filter. Dust collector is located under air filter.

1.6.4

Clean and check the crankcase breather tube

Instructions 1 2 3 4

Remove the crankcase breather tube from the breather vent tube. Use solvent to clean the inside of the crankcase breather tube, and dry with compressed air. Use air pressure to blow through the vent tube. Replace the vent tube if it is clogged.

1.6.5

Check the vibration damper

Instructions

CAUTION The silicone fluid in the damper will become solid after extended service and will make the damper inoperative. An inoperative damper can cause major engine or driveline failures.



17

Check the dampers for evidence of fluid loss, dents, and wobble. Inspect the vibration damper thickness for any deformation or rais‐ ing of the damper front cover plate.

1.6.6

Check the fan hub bearing clearance

Instructions Fan hubs with "stepbore" shafts and no bearing spacers must be 0.08 to 0.25 mm [0.003 to 0.010 in] end clearance. Fan hubs with "through-bore" shafts with inner and outer bearing spacers must be 0.08 to 0.41 mm [0.003 to 0.016 in] end clearance.


1 Cummins – 1.7 Cooling system

18

1.7

Cooling system

Flow diagrams, cooling system 7 3 6

1. 2. 3. 4. 5. 6. 7.

Coolant inlet Coolant flow from coolant filter Coolant by-pass flow from thermostat Coolant flow to water pump Coolant flow from water pump Coolant flow past oil cooler Coolant flow to cylinder head

A) B) C) D) E) F) G)

Coolant flow from cylinder block to cylinder head Coolant flow from cylinder head to thermostat housing Coolant flow to radiator Coolant by-pass passage Coolant by-pass flow to water pump Coolant by-pass Closed Thermostats

6 1 2

3

5

4

C

D

A B B

D

C

B

E G F



1.7.1

19

Checking the coolant level

Instructions

CAUTION Do not open the radiator cap (1) when the engine is hot. Steam or hot coolant may be discharged from the radiator and cause burns. Open the cap carefully, and wait for the fluid to cool down before add‐ ing fluid.

1

The engine must be turned off at least 30 minutes before the inspection. Open the cap of the tank carefully. The coolant should be at the level of the cap hole (1). If necessary, add coolant using the filling pump (2).

2

1.7.2

Changing the coolant filter

Instructions

CAUTION Open the cap of the tank carefully when the engine is warm. Steam or hot coolant may be discharged from the radiator and cause burns. Be careful when draining the cooling system; coolant at the operating temperature may cause burns.


20


IMPORTANT Be careful not to discharge coolant into the environment. Use an appropriate container, and deliver the coolant to a hazardous waste collection point.

NOTE While changing the coolant filter, the on/off valve must be in the OFF position. Then the coolant flow is cut off to and from the coolant filter. 1 2 3 4

Open the radiator pressure cap. Remove and discart the coolant filter. Clean the gasket surface of the filter head. Apply a thin film of clean engine oil to the filter gasket sealing surface before installing the filter.

NOTE After installing the coolant filter, the ON mark on the coolant filter col‐ lar must be properly aligned. 5 6

Tighten the coolant filter 1/2 of a turn after initial gasket con‐ tact. Install the radiator cap.

Operate the machine until the coolant tempetature is above 82 °C (180 °F), and check for coolant leaks. After the air has been purged from the system, check the coolant level again.

1.7.3

Changing the coolant and flushing the cooling system

Instructions

CAUTION Open the cap of the tank carefully when the engine is warm. Steam or hot coolant may be discharged from the radiator and cause burns. Be careful when draining the cooling system; coolant at the operating temperature may cause burns.



21

IMPORTANT Be careful not to discharge coolant into the environment. Use an appropriate container, and deliver the coolant to a hazardous waste collection point.

1

1 2 3

4

Open the radiator pressure cap carefully. Drain the coolant into the container through the drain valve. Use the hand pump to fill the system with clean, hot water into which you have mixed radiator cleaner. Follow the radiator cleaner manufacturer’s instructions. Fill the system with new coolant; for the coolant type, see chapter F Technical data.The coolant should be at the level of the cap hole (1). Add coolant using the filling pump (2).

The engine must be turned off at least 30 minutes before the check‐ ing the coolant level.

2

1.7.4

External cleaning of the radiator

Instructions Clean the radiator with a steam cleaner and rinse with running water.

NOTE Do not use high pressure; this might damage the radiator.


22

1 Cummins – 1.8 Lubrication system

1.8

Lubrication system

Component position, Lubricating oil system

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Lubricating oil flow from oil pan through suction tube Flow from suction tube to oil pump Pressure regulator High-pressure relief valve Flow from oil pump to oil cooler/filter head housing Oil return from oil cooler/filter head housing to main oil rifle Main oil rifle Flow to main bearing Flow from main bearing to crankshaft Flow to cylinder head Flow to piston cooling nozzle Flow to idler gears Oil transfer from main oil rifle Flow to air compressor Rifle sensing regulator pump to inlet



1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

23

Lubricating oil flow from cylinder block to cylinder head Flow around grooved head to drilled camshaft and rocker lever shafts Flow to injector rocker lever shafts Flow to injector rocker levers Flow to injector camshaft journal bearings Flow to fuel pump Flow to valve rocker lever shafts Flow to valve rocker levers Flow from valve camshaft journal bearings Intake valve rocker lever Engine brake lever Exhaust valve rocker lever Injector rocker lever Oil drain from overhead (front and rear)


24


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Lubricating oil flow from oil pump Thermostat Oil cooler by-pass flow Flow through oil coolers Flow return to filter head Filter by-pass valve Oil filter Flow to turbocharger Flow to main oil rifle Oil drain from turbocharger Thermostat open - oil flows through oil coolers Thermostat closed - oil flows directly to oil filter Flow to oil filter

1.8.1

Checking the oil level

Checking the oil level

IMPORTANT Ensure absolute cleanliness. Impurities in oil cause damage to the system.


1 Cummins – 1.8 Lubrication system 1

2 MAX MIN

1

2 3

25

The engine must be turned off at least 30 minutes before the inspection. Clean the dipstick (2) and check the oil level. The oil level must be between the marks on the dipstick. If necessary, add oil through the refilling point (1). For the oil type, see Chapter F Technical data.

2

1.8.2

Replacing the oil filter

Instructions

CAUTION Avoid skin contact with oil. Use protective gloves.

IMPORTANT Be careful not to discharge oil into the environment. Use an appropri‐ ate container, and deliver the oil and the used filter to a hazardous waste collection point. Ensure absolute cleanliness. Impurities in oil cause damage to the system.


26

1 Cummins – 1.8 Lubrication system 1 2 3 4 5

Place the container below the filter for the oil that flows out. Clean the filter and the area around it. Remove the filter. Lubricate the rubber seal of the new filter with a small amount of engine oil. Tighten the new filter element into place to an additional 3/4 turn after the gasket contacts the filter head surface.

NOTE The o-ring can stick on the filter head. Make sure it is removed.

NOTE If the lubricating oil filter head adapter comes off during the removal, reinstall it by using a small amount of loctite on the threads. 6

Start the engine, and check the filter for leaks.

1.8.3

Changing oil

Instructions


IMPORTANT Be careful not to discharge oil into the environment. Use an appropri‐ ate container, and deliver the oil and the used filter to a hazardous waste collection point. Take care to ensure absolute cleanliness. Impurities in oil cause damage to the system.



2

1 2 3

4

1

3

27

Run the engine until it is warm. Drain the oil with the hand pump (3) into a container. Fill the engine with oil through the filler point (1) until the oil level is between the marks on the dipstick (2). For the oil vol‐ ume and type, see chapter F Technical data. Run the engine for about 30 seconds, and check the oil level. Refill if necessary.

2


28



1

Table of content 2 Transmission

3

2.5 Electrical transmission 2.5.1 Checking the generator mounting


3 4

2


2 Transmission – 2.5 Electrical transmission

2

3

Transmission

General This chapter describes the generator, which generates the electric power used to run the machine’s electric transmission system.

2.5

Electrical transmission

Safety

DANGER Danger! High voltage! The electric systems must be serviced and repaired by trained per‐ sonnel. For safety instructions, see Chapter B,section Electric systems.

Description

A

Single speed generator A diesel engine runs the generator A at a constant speed of 1500/1800 rpm. The generator generates three-phase alternating current (400/440 VAC) with a frequency of 50/60 Hz. The electric power is used to run the electric drive motors. Variable speed generator (VSG) With VSG-RTG the generator output voltage and frequency will vary depending on the diesel engine rpm. Regardless the diesel engine


2 Transmission – 2.5 Electrical transmission

4

rpm, the voltage and frequency supplied for auxiliary loads (for example, lighting and air conditioning) are kept constant. Typically engine speed varies between 900…1800rpm and auxiliary loads voltage is 400/440VAC with a frequency of 50/60Hz.

2.5.1

Checking the generator mounting

Instructions 1 2 3 4 5

Remove the protective net. Tighten the flex plate mounting screws (1), tightening torque 80 Nm. Tighten the generator mounting screws (2). Install the net back in place. Check the condition of the vibration dampers (3).

3

2 1

80 Nm


1

Table of content 3 Driveline/axle

3

3.1 Checking tightening torques of the driveline/axle

3

3.2 Drive shaft 3.2.1 Checking a cardan shaft

5 5

3.2.2 Replacing a cardan shaft

6

3.3 Driven wheel 3.3.1 Checking the wheel hub and the angle gear lubrication oil level 3.3.2 Changing the lubrication oil

7 8 8

3.3.3 Changing a driven wheel

10

3.3.4 Lubrication points

12

3.4 Non-driven wheel 3.4.1 Checking the wheel hub lubrication oil level

14 14

3.4.2 Changing the lubrication oil

15

3.4.3 Changing a non-driven wheel

16

3.6 Electrical drive 3.6.1 Component position

19 26


2


3 Driveline/axle – 3.1 Checking tightening torques of the driveline/axle

3

3

Driveline/axle

General The driveline/axle consists of the electric transmission from the gen‐ erator to the drive motors and the mechanical transmission from the drive motors to the wheels.

3.1

Checking tightening torques of the driveline/axle

Instructions

6 7

4

5

6

5

5

5

3 8 6

6

4

6


6

4

3 Driveline/axle – 3.1 Checking tightening torques of the driveline/axle

1. 2. 3.

4.

Do a full cleaning of the inspected area. Check every screw and nut of items from 4 to 8 of the figure shown above. Check visually for any defects. Possible defects are: loose screws or nuts • damage • cracks • deformations • corrosion • Use a tap testing for screws without a nut. Hit screws lightly with a tap test hammer and listen the sound (or use an analysis instrument). If a screw is damaged or the prestress is low, the sound is lower compared to an undamaged, sufficiently tight screw.

Replace a defect screw or nut with a new one with all the character‐ istics of the original. Check tightening torques from Chapter F Technical data.

NOTE Never retighten a loose screw or nut.


3 Driveline/axle – 3.2 Drive shaft

3.2

5

Drive shaft

Description A cardan shaft transmits the power from the electric drive motors to the angle gear on the wheel hub.

3.2.1

Checking a cardan shaft

Instructions

67Nm

67Nm

Fig. : Tightening torques

1 2

Tighten the cardan shaft mounting screws. Check the joints for play.


3 Driveline/axle – 3.2 Drive shaft

6

3.2.2

Replacing a cardan shaft

Instructions

CAUTION Use appropriate lifting equipment for handling a removed shaft.

C

B

A

1 2 3

Detach the lower end of the cardan shaft from the hub, point A. Detach the drive motor from the fork and lift it away with the cardan shaft, point B. Detach the upper end of the cardan shaft from the drive motor, point C.


3 Driveline/axle – 3.3 Driven wheel

3.3

7

Driven wheel

Description

1 2

The axle includes the wheel hubs (1) and the angle gear (2) on the hubs of the driven wheels. The power is transmitted to the wheel via the angle gear and the planetary gear integrated into the wheel hub.



8

3.3.1

Checking the wheel hub and the angle gear lubrication oil level

Instructions

75 °

180 °

2

3 2

1 2 3

1

1

Remove the cover (3). Clean the wheel hub. Turn the wheel into a position where the wheel hub drain hole (1) is about 15° below the centre line of the gear unit as shown in figure.

NOTE In one series of Wheel gear units there are two oil plugs located at 75 ° and in the other series there are oil plugs located at 180°. 4 5

6

Remove the plug (1). The oil level must be at same level as the fill hole 1. Add oil if necessary. Wait a few minutes for the oil to flow to the angle gear. The oil type is the same like the wheel hub, see Chapter F Technical data. Reinstall the plug and the cover.

3.3.2

Changing the lubrication oil

General




9

IMPORTANT Be careful not to discharge oil into the environment. Use an appropri‐ ate container, and deliver the oil to a hazardous waste collection point. Take care to ensure absolute cleanliness. Impurities in oil cause damage to the system. Driven wheel

75 °

180 °

2

3 2 2

180

°

1

1 75 °

2 1

1 2 3

1

Remove the cover (3). Clean the wheel hub. Turn the wheel into a position where the wheel hub drain hole (1) is at the lowest position.

NOTE In one series of Wheel gear units there are two oil plugs located at 75° and in the other series there are oil plugs located at 180°. 4 5 6

7

Remove the plugs (1) and (2). Drain the oil into a container through the drain hole (1). Turn the wheel into a position where the wheel hub drain hole (1) is about 15° below the centre line of the gear unit as shown in figure. Fill the hub with lubrication oil up to the level of the filling hole (1) untit it has reach the level of the plug (2). The oil type is the same like the wheel hub, see Chapter F Technical data.



10

8

Reinstall the plugs and the cover.

3.3.3

Changing a driven wheel

General

IMPORTANT Check that the ground is straight and flat under jack. Pay attention to the cleanness of rim, wheel hub and wheel nuts. Any paint, oil or grease on these surfaces prevents proper tightening of wheel nuts. Loose nuts allow rim to move which causes severe dam‐ age to hub.

Lifting equipment

Qty

Bottle jack

1

Turn stopper, L=80 mm

1

Support, L=2825 mm

1

Support, L=140 mm

4

Changing a driven wheel (A) 1

Put the bottle jack (B) under the running wheel fork (A-A).

B A

A. B.

Driven wheel Non-driven wheel

A

B

A-A


3 Driveline/axle – 3.3 Driven wheel 2 3

D

4

Lift with the bottle jack 160 mm. Fix the support (C) with plates and bolts to the plate under the sill beam (C-C). Add the turn stopper (D).

5 6 7

Add the support (E) under the jack. Lift with the jack 160 mm. Add the support (F) under the support (C).

8 9 10

Add the second support (G) under the jack. Lift with the jack 160 mm. Add the second support (H) under the support (C).

C

C-C

C

E

F

C

G

11

H


12


3.3.4

Lubrication points

Angle transmission

Manual lubrication Central lubrication If the machine is not equipped with a central lubrication system

Manual greasing, gantry motor

1

1


=


13

Pos

Lubrication points, gantry motor

Qty

1

Bearings of gantry motor (volume 40g)

2

NOTE Use specified grease for motor bearings. More information from the Secton F of this manual and from the information plate of the motor.


3 Driveline/axle – 3.4 Non-driven wheel

14

3.4

Non-driven wheel

Description

1

The axle includes the wheel hubs (1).

3.4.1

Checking the wheel hub lubrication oil level

Non-driven wheel

3

75 °

180 °

2

2

1 2 3

1

1

Remove the cover (3). Clean the wheel hub. Turn the wheel into a position where the wheel hub drain hole (1) is about 15° below the centre line of the gear unit as shown in figure.

NOTE In one series of Wheel gear units there are two oil plugs located at 75 ° and in the other series there are oil plugs located at 180°. 4

Remove the plug (1).


3 Driveline/axle – 3.4 Non-driven wheel 5

6

15

The oil level must be at same level as the fill hole 1. Add oil if necessary. Wait a few minutes for the oil to flow to the angle gear. For non-driven wheels, wait a few minutes for the oil to flow to the wheel hub. See the oil type Section F Technical data. Reinstall the plug (1) and the cover.

3.4.2

Changing the lubrication oil

General


IMPORTANT Be careful not to discharge oil into the environment. Use an appropri‐ ate container, and deliver the oil to a hazardous waste collection point. Take care to ensure absolute cleanliness. Impurities in oil cause damage to the system. Non-driven wheel

75 °

180 °

2

3 2 2

180

°

1

1 75 °

2 1

1 2

Remove the cover (3). Clean the wheel hub.


1


16

3

Turn the wheel into a position where the wheel hub drain hole (1) is at the lowest position.

NOTE In one series of Wheel gear units there are two oil plugs located at 75° and in the other series there are oil plugs located at 180°. 4 5 6

7

8

Remove the plugs (1) and (2). Drain the oil into a container through the drain hole (1). Turn the wheel into a position where the wheel hub drain hole (1) is about 15° below the centre line of the gear unit as shown in figure. Fill the hub with lubrication oil up to the level of the filling hole (1) untit it has reach the level of the plug (2). The oil type is the same like the wheel hub, see Chapter F Specifications. Reinstall the plugs and the cover.

3.4.3

Changing a non-driven wheel

General

IMPORTANT Check that the ground is straight and flat under jack. Pay attention to the cleanness of rim, wheel hub and wheel nuts. Any paint, oil or grease on these surfaces prevents proper tightening of wheel nuts. Loose nuts allow rim to move which causes severe dam‐ age to hub.

Lifting equipment

Qty

Bottle jack

1

Turn stopper, L=80 mm

1

Support, L=2825 mm

1

Support, L=140 mm

4

Instructions 1

Put the bottle jack (B) under the driving wheel fork (B-B).

B A

A. B.

Driven wheel Non-driven wheel



B-B

A

B

2 3

D

4

Lift with the bottle jack 160 mm. Fix the support (C) with plates and bolts to the plate under the sill beam (D-D). Add the turn stopper (D).

5 6 7

Add the support (E) under the jack. Lift with the jack 160 mm. Add the support (F) under the support (C).

C

D-D

C

E

17

F



18

8 9 10

Add the second support (G) under the jack. Lift with the jack 160 mm. Add the second support (H) under the support (C).

C

G

H


3 Driveline/axle – 3.6 Electrical drive

3.6

19

Electrical drive

Safety

DANGER Danger! High voltage! The electric systems must be serviced and repaired by trained per‐ sonnel. For safety instructions, see Chapter B, section Electric systems.

Description Diesel generator power supply: Electrical transmission consists of AC-Generator, rectifier, inverters and electric drive motors. System is powered by the AC-generator, which is run by a diesel engine. Zero emission power supply: Electrical transmission consists of rec‐ tifier, inverters and electric drive motors. System is powered by external power source through a cable. Crane is equipped with medium voltage transformer if power supply voltage is more than 1 kV. PLC verifies with proximity switches that wheel positions are correct on all corners and permits driving. Driving speed is adjusted by gantry Joystick located at operator´s cabin; inverters adjust the speed of the motors on the basis of joy‐ stick position. When Joystick is moved, gantry brakes are opening and they stay open until driving speed goes back to zero then brakes will close. When braking (decelerating), gantry motors are acting as electrical brakes, command of braking comes when gantry joystick goes to neutral position. Diesel generator power supply: Re-generative power from the motors are fed to DC-link where braking units feed all excess energy to braking resistors, which are transferring braking energy to heat. Zero emission power supply: Re-generative power from the motors are fed to DC-link where Active Interface Module (AIM) feeds all excess energy to electricity distribution network. PLC system is checking machine vicinity with cat-whisker type switches or ultra-sonic/laser sensors, when machine is too close to objects it will stop movement immediately.



20

Function description (diesel generator power supply) PLC

PLC

8

9, 18

14

17

15 16

1 600 - 625 VDC

2 3

G

6 ~

5

7

7

~

~

19

U

U

4

300 - 425 VAC

11

11

M~ 3

°C

12

11

11

M~ 3

10, 21

°C

12

M~ 3

10, 21

PG

PG

13

13

°C

12 10, 21

M~ 3

°C

12 10, 21 20 20

Item numbers in parentheses refer to the circuit diagram.


19


Pos

Function

Signal description

1

The diesel engine generates electrical power required by the AC-generator.

2

The AC-generator (G01) produces electrical power to the system.

400 – 440 VAC, 50 – 60 Hz

3

Main circuit breaker (F01) protects the system from overload and short-circuit currents.

400 – 440 VAC, 50 – 60 Hz

4

Generator supply contactor (K51) connects AC-generator´s output to the RTG electrical system.

400 – 440 VAC, 50 – 60 Hz

5

Main fuses (F2) protect the rectifier from short-circuit currents.

400 – 440 VAC, 50 – 60 Hz

6

Rectifier (U5) converts alternating current into direct current for the direct current intermediate circuit (DC-link).

400 – 440 VAC / 540 – 600 VDC

7

Inverters (U1 and U2 or U2 and U3) receive the electric power from the DClink and convert DC power into adjustable frequency AC power.

540 – 600 VDC / 400 – 440 VAC, 0 – 58 Hz

8

PLC verifies wheel positions by proximity switches (S106,S107, S108, S109, S110, S111, S206,S207, S208, S209, S210 and S211).

Proximity switch – PLC: 24 VDC

9

Gantry joystick (S701 or S731) sends setpoint signal to inverters via Profibus.

Joystick – PLC: 24 VDC PLC – inverter: Profibus

10

Brakes (Y101, Y102, Y203 and Y204) will open when inverters start to control the motors.

PLC – brake contactor: 24VDC 230 VAC, 50 – 60 Hz (8 wheels) 400 VAC, 50 – 60 Hz (16 wheels)

11

Inverters control the direction of rotation and speed of the drive motors (M101, M102, M203 and M204).

~ 0-400 VAC, 0 – 58 Hz

12

PLC monitors the temperature of the drive motors with temperature sensors.

Inverter – PLC: Profibus


21

Reference


22

Pos

Function

Signal description

13

PLC monitors the speed of the motors with the pulse encoders (B101 and B203) on the motors.


PLC

by

Whisker-switch – PLC: 24 VDC

by

Ultrasonic sensor – PLC: 24 VDC

14

monitors

anti-collision

catwhisker switches 15

PLC

monitors

anti-collision

ultrasonic sensors 16

.

.

PLC monitors anti-collision by laser sensors

Laser sensor – PLC: 24 VDC

.

17

Manual steering switch (S702) gives steering command to PLC, which slows down the setpoint signal for Inner wheel side.


18

When braking, gantry motors are acting as electrical brakes, command of braking comes when gantry joystick goes to neutral position.


19

Regenerative energy generated during braking is fed via DC-link to braking units (A1 and A2)

~680 VDC

20

Braking units feed excess energy to braking resistors (R91), which are transferring braking energy to heat.

~680 VDC

21

When motors are stopped (rotation speed zero), brakes (Y101, Y102, Y203 and Y204) close.

PLC – Brake contactor 24 VDC Brake contactor – Brake 400 VAC, 50 – 60 Hz


Reference


23

Function description (zero emission power supply) PLC

PLC

9

10, 19

15

18

16 17

1, 21

540 - 600 VDC

7

2

~

20 3

6

8

8

~

~

5

4

400 - 440 VAC

12

12

M~ 3

°C

13

12

M~

°C

3

11, 22

13

12

M~ 3

11, 22

PG

PG

14

14

°C

13 11, 22

M~ 3

°C

13 11, 22




24

Pos

Function

Signal description

1

Electrical power is supplied from external power source through a cable.

See chapter F Technical data for supply voltage

2

Electrical power is led through a power supply connection box.


3

Medium voltage transformer transforms the supply voltage into a lower voltage. Transformer is applicable only when the power supply from external power source over 1 kV.


4

Main circuit breaker (F150) protects the system from overload and shortcircuit currents.

400 – 440 VAC, 50 – 60Hz

5

Main supply contactor (K50) connects external power supply to the RTG electical system.

400 – 440 VAC, 50 – 60Hz

6

Main fuses (F2) protect the rectifier from shortcircuit currents.

400 – 440 VAC, 50 – 60Hz

7


400 – 440 VAC / 540 – 600 VDC

8

Inverters (U1 and U2 or U2 and U3) receive the electric power from the DC-link and convert DC power into adjustable frequency AC power.

540 – 600 VDC / 400 – 440 VAC, 0 – 58 Hz

9

PLC verifies wheel positions by proximity switches (S106,S107, S108, S109, S110, S111, S206,S207, S208, S209, S210 and S211).


10

Gantry joystick (S701 or S731) sends setpoint signal to inverters via Profibus.


11

Brakes (Y101, Y102, Y203 and Y204) will open when inverters start to control the motors.

PLC – brake contactor: 24VDC Brake contactor – brake: 230 VAC, 50 – 60 Hz (8 wheels) 400 VAC, 50 – 60 Hz (16 wheels)

12

Inverters control the direction of rotation and speed of the drive motors (M101, M102, M203 and M204).

~ 0-400 VAC, 0 – 58 Hz

13

PLC monitors the temperature of the drive motors with temperature sensors.


14

PLC monitors the speed of the motors with the pulse encoders (B101 and B203) on the motors.


15

PLC monitors anti-collision by catwhisker switches

Whisker-switch – PLC: 24 VDC

.



Pos

Function

Signal description

16

PLC monitors anti-collision by ultrasonic sensors

Ultrasonic sensor – PLC: 24 VDC

. 17

PLC monitors anti-collision by laser sensors

18

Manual steering switch (S702) gives steering command to PLC, which slows down the setpoint signal for Inner wheel side.


19

When braking, gantry motors are acting as electrical brakes, command of braking comes when gantry joystick goes to neutral position.


20

Regenerative energy generated during braking is fed via DC-link to Active Interface Module (AIM) (U7).

~680 VDC

21

AIM unit feeds all excess energy to electricity distribution network.

22

When motors are stopped (rotation speed zero), brakes (Y101, Y102, Y203 and Y204) close.

.

Laser sensor – PLC: 24 VDC



25


26

3.6.1

Component position

Overview

3

4

2

1

3

4 2

1

1. 2. 3. 4.

Diesel Engine/Generator Electric centre, EE-house Wheel turning motors Drive motors For component positions of Zero Emission RTG; see chapter11 Common electrics.


1

Table of content 4 Brakes

3

4.3 Service brake system 4.3.1 Checking and adjusting the gantry brake

3 4

4.3.2 Checking and adjusting the steering brake

6

4.3.3 Checking and adjusting the trolley brake

7

4.3.4 Checking and adjusting the hoist brake

9

4.3.5 Checking and adjusting the skew brake

16

4.3.6 Checking and adjusting the trim brake (option)

18

4.3.7 Checking and adjusting the cable reel brake (Zero Emission RTG)

20


2


4 Brakes – 4.3 Service brake system

4

3

Brakes

Description Gantry,steering, trolley, skew and trim eletrically by brake motor.

travel braking are done

Hoist brake is of spring loaded / electro hydraulic released type operated disk brake type.

Component position 6 5

6 5

4

7 3

2 2 1

1 2 1

2 1

1. 2. 3. 4. 5. 6. 7.

Gantry brake Steering brake Trolley brake Hoist brake Skew brake Trim brake Cable reel brake (Zero Emission RTG)

4.3

Service brake system

Description The hoisting system is equipped with one or two operational hoist brakes and optionally with emergency hoist brakes. The brakes are spring-loaded, fail-safe disc brakes. The operational hoist brake and the emergency hoist brake are both applied in case of an emer‐ gency stop. The operational hoist brake acts on the input shaft of the gearbox. The brake is applied when hoisting or lowering is not activated. The Maintenance manual 308 001 EN

4

4 Brakes – 4.3 Service brake system brake is released by an electro-hydraulic thruster when hoisting or lowering is activated. The brake is equipped with a manual releas‐ ing. Optional emergency hoist brake acts directly on the hoist drum. The brake prevents the load from falling in case of emergency. The brake is released by a hydraulic pressure produced by a hydraulic unit. The hydraulic unit is equipped with a hand pump with which the brake can be released manually. Gantry brakes, steering brakes, trolley brakes, skew brakes, and trim brake (option) are springoperated single disc brakes with two friction surfaces. The brake torque is generated by several compres‐ sion springs by friction. The brakes are released electromagneti‐ cally.

4.3.1

Checking and adjusting the gantry brake

Instructions In normal application, the brake is practically maintenance-free. Only in applications that involve extremely high frictional work, the air gap S1 has to be checked at defined intervals and readjusted to the nominal value S1n before the maximum air-gap S1m is excee‐ ded (see figure).

NOTE Before commissioning, it must be checked in the de-energized state that the air-gap is uniform and equal to the nominal size using a feeler gauge between the armature disk and magnetic section at 3 points on the circumference.

NOTE When the motor is recommissioned, the brake must be checked for correct operation!



3

5

2

4

5

1

S2 = 2,5mm

S1 = 0,5 mm (S1n) (min 0,5 mm) (S1m) (max 1,5 mm) h = min15,5mm)

The air gap is adjusted as follows: 1 Remove fan cover 1. 2 Loosen fixing screws 2, screw adjustment bushes 3 into the magnetic section 4 using a fixed spanner and tighten the fix‐ ing screws again. 3 Then check the air-gap again.

NOTE Frictional surfaces must not come into contact with oil or grease!


6

4 Brakes – 4.3 Service brake system Replacing the friction coating has been consumed, the rotor 5 must be replaced. See figure for minimum rotor thickness h.

NOTE Dimensional S2 must be observed!

4.3.2

Checking and adjusting the steering brake

Instructions

NOTE Air gap (a + 0,1mm) needs not to be readjusted

a + 0,1mm



4.3.3

7

Checking and adjusting the trolley brake

Instructions

CAUTION Do not leave lever in the brake. Tripping hazard. In normal application, the brake is practically maintenance-free. Only in applications that involve extremely high frictional work, the air gap S1 has to be checked at defined intervals and readjusted to the nominal value S1n before the maximum air-gap S1m is excee‐ ded (see figure).





8

2

3

4

5

1

S2 = 2,5mm

S1 = 0,5mm (S1n) (min 0,5mm) (S1m) (max 1,5mm) h = min 15,5mm

The air gap is adjusted as follows: 1 Remove fan cover 1. 2 Loosen fixing screws 2, screw adjustment bushes 3 into the‐ magnetic section 4 using a fixed spanner and tighten the fix‐ ing screws again. 3 Then check the air-gap again.

NOTE Frictional surfaces must not come into contact with oil or grease! Replacing the friction coating has been consumed, the rotor 5 must be replaced. See figure for minimum rotor thickness h.



9


4.3.4

Checking and adjusting the hoist brake

Safety

DANGER Immediate risk of crushing. Always use the safety switch with a lock when servicing the hoist brake. The safety switch prevents the hoist brake from releasing during the service. 4.3.4.1

Checking brake alignment

General Misalignment of the brake can cause weak contact pressure between brake pads and disc and lead to lowered braking torque. For that reason, it's very important that the brake is correctly aligned. Instructions

1

2

4 3

7

5

6 1

2

Check that the linkage of the brake works properly, e.g. that there is no bending in the brake arms or top levers when the brake is releasing. Misalignment of the brake can also be rec‐ ognized from uneven wear of the disc and the brake pad lin‐ ings. If necessary, adjust with following steps. In case of unevenly worn brake pad linings, the brake pads must be replaced before alignment. For instructions, see Appendixes, section Hoist brake. Remove the wedge (1).



10

3

Release the brake spring completely by turning the adjust‐ ment nut (2) counterclockwise. Remove the catch (3) by unscrewing the fastening screw (4).

4

NOTE Turning the reserve stroke adjustment nut (5) in following step may damage the AWC (automatic wear compensator) if the catch is in its place. 5 6 7

8 9

A

10 11 12 13

9

14

Turn the adjustment nut (5) counterclockwise to move brake pads away from disc. Loosen the brake mounting bolts (6). Rotate the adjustment nut (2) clockwise until the upper edge of the torque indicator (7) shows about 1/3 of the nominal braking torque (see brake’s type plate for braking torque). Turn the adjustment nut (5) clockwise to press the brake pads against the disc. Brake aligns itself to the brake disc. Check that the brake disc's (8) edge exceeds the brake pads (9) by 5 mm (A). Measure from the outer edge of the brake pad, not from the brake pad carrier. If necessary, adjust by moving the brake. Check brake alignment. Insert wedge (1) loosely and without force into the guide way. Reinstall the catch (3). Tighten the brake mounting bolts (6) with tightening torque of 655 Nm. Adjust braking torque and thruster’s reserve stroke, see chap‐ ters Checking the braking torque and Checking the reserve stroke of the thruster.

8 4.3.4.2

Checking the air gap between brake pad and brake disc

General The brake is equipped with a centering device, which centers the brake automatically when the brake pads are wearing down. In case of considerably unequal brake pad lift-off, an adjustment is neces‐ sary.



11

Instructions

3 2

1

1 2

Release the brake with thruster. Check the air gap between brake pads and brake disc. If the gaps are considerably unequal, adjust with following steps. Remove the cover (1). Remove the adjusting screws (2) and clean the threads from any adhesive agent. Tighten the adjusting screws (2) evenly with a screwdriver (air gap = 0), afterwards loosen the screws one quarter rotation. Insert wedge (3) loosely and without force into the guide way. Actuate and release the brake several times until the wedge (3) doesn’t move further down. Check that the air gap is equal on both sides of the brake disc.

3 4 5 6 7 8

If the air gap is too large on the stop side of the brake, turn both adjusting screws (2) clockwise. “Stop side” means the side of the brake which is equipped with the wedge (3). If the air gap is too large on the opposite side, turn both adjusting screws (2) counterclockwise. 9 10 11 12 13

Adjust by turning the adjusting screws with very small steps. Activate the self centering device with following steps. Release the brake. Insert wedge (3) loosely and without force into the guide way. Actuate and release the brake several times until the wedge (3) doesn’t move further down. Reinstall the cover (1).


12

4 Brakes – 4.3 Service brake system 4.3.4.3

Checking the lining wear / lining thickness

General

IMPORTANT The sintered lining will tend to accumulate dust particles which can reduce the friction factor and thus the available braking torque. These dust particles in the brake pad surface can be removed by carrying out the annual dynamic brake test. If it is not possible to carry out dynamic load tests at regular intervals, it is recommended to change brake pads every 2 years. If brake pads removed from the brake are in otherwise good condition i.e. free from oil contamination, even wear pattern, no visible cracks or deformation and well above mini‐ mum residual pad thickness, they can be reconditioned by grinding or machining approximately 0,5 mm off the surface. Instructions Minimum allowable thickness of the linings: • •

Glued linings: 3 mm Riveted linings / Glued and riveted linings: 5 mm

When the minimum thickness has been reached, the brake pads must be replaced and run in properly. For instructions, see Appen‐ dixes, section Hoist brake. 4.3.4.4

Checking the condition of the brake disc

Instructions Check the disc for: • •

Grease and rust. Clean the disc if necessary. Uneven grooves and crack. If considerably uneven grooves or cracks are found, please contact Cargotec service personnel.

4.3.4.5

Checking the reserve stroke of the thruster

General Thruster ‘s stroke requires certain reserve to generate proper con‐ tact pressure between brake pads and disc. Without reserve stroke the spring force is guided to the thruster itself and not to the brake pads. For that reason is very important that the reserve stroke is correctly adjusted to achieve maximum braking torque.



13

Instructions

3 2 A 4

1

5

1 2

3

Release the brake with thruster. Measure the distance (A) between thruster frame and piston rod as shown in the figure. Correct distance is 155 mm (+3 / -1 mm). The lower edge of the cap has to be at the center of the notch “10” (1). If necessary, adjust with following steps. Remove the catch (2) by unscrewing the fastening screw (3).

NOTE Adjusting the reserve stroke may damage the AWC (automatic wear compensator) if the catch is in its place during procedure. 4 5 6

Adjust the distance A to 155 mm with the adjustment nut (4). Apply the brake. Reinstall the catch (2). Ensure that the catch pin (5) is within the catch.



14

4.3.4.6

Checking the braking torque

Instructions Check the braking torque from the scale (1) while the brake is applied. Torque is correctly adjusted when the upper edge of the indicator shows approximately 90% of the rated maximum braking torque. For braking torque, see chapter F, Technical data. If neces‐ sary, adjust by turning the adjusting nut (2).

1

NOTE The permissible minimum braking torque is 50% of the rated maxi‐ mum braking torque. If the whole brake is replaced, ensure that the braking torque marked on new brake’s type plate corresponds to old one.

2

4.3.4.7

Checking the adjustment of limit switches and manual release devices

Safety

CAUTION Limit switches must not be put out of service, overridden or blocked in any other way. Otherwise the safe use of the brake is no longer given. Control for brake status (released/applied) The limit switch (1) is mounted to the spring tube. For the limit switch there is an actuating roll (2) screwed onto a threaded rod. Figure shows the brake applied. When the brake releases, the threaded rod moves upwards. The actuating roll activates the limit switch when the brake is released.

1

2



15

Wear control The limit switch (1) is mounted into the crosspiece (2) of the AWC. When the brake is set correctly, the switch is not activated. With growing wear, the spindle (3) moves into the crosspiece. As soon as the wear reaches the critical value, the limit switch is actuated.

2 3

1

Manual release device Check the function and condition of the manual release device. 4.3.4.8

Checking the AWC (Automatic Wear Compensator) for wear

Instructions The catch (1) and the freewheel (2) may be objects to wear. Wear‐ ing can be recognized from constant reduction of the reserve stroke in case of lining wear, although the AWC is actuated. In case of wear, proceed as follows:

1

1

3

2

Rotate nut (3) clockwise to compensate lining wear and thus the reduced reserve stroke, see section Checking the reserve stroke of the thruster. Replace worn parts respectively and the complete AWC unit as soon as possible. For instructions, see Appendixes, sec‐ tion Hoist brake.

2 4.3.4.9

Checking the operation of the hoist brake / brake system

Instructions Check visually the operation of the brake system for braking dis‐ tance etc. If necessary, check and repeat brake adjustment. 4.3.4.10

Dynamic brake test

Instructions Carry out 3 – 4 braking cycles at maximum lowering speed with no load attached to the spreader. 4.3.4.11

Static brake test for system with two hoist brakes (option)

Instructions 1 2

Attach a test load (SWL) to the spreader. Lift the load approximately 30 cm off the base.


16

4 Brakes – 4.3 Service brake system 3

Release one brake at a time using a manual release. The second brake must hold the load safely. If necessary, check and repeat brake adjustment.

4.3.5

Checking and adjusting the skew brake

Instructions

DANGER Immediate risk of crushing. Always use the emergency switch on the trolley when servicing the skew gear. The emergency switch prevents the skew gear from operating during the service. In normal application, the brake is practically maintenance-free. Only in applications that involve extremely high frictional work, the air gap S1 has to be checked at defined intervals and readjusted to the nominal value S1n before the maximum air-gap S1m is excee‐ ded (see figure).





17

2

3

4

5

1

S2 = 2mm






18


4.3.6

Checking and adjusting the trim brake (option)

Safety

A

B

The trim must be secured from moving during maintenance by lock‐ ing the trim wheel in place. Push the locking pin through the locking holes (B) in the frame and trim wheel.

CAUTION If the trim wheel is not locked in place during maintenance, the trim may move causing safety hazard.

A. B.

locking pin storage locking hole

WARNING The locking pin must be removed and placed to it’s storage before taking the trim into use. Otherwise the locked trim wheel may cause damage to the trim motor. Instructions In normal application, the brake is practically maintenance-free. Only in applications that involve extremely high frictional work, the air gap S1 has to be checked at defined intervals and readjusted to the nominal value S1n before the maximum air-gap S1m is excee‐ ded (see figure).





19

2

3

4

5

1

S2 = 1,5mm





20



4.3.7

Checking and adjusting the cable reel brake (Zero Emission RTG)

Instructions For instructions, see Appendixes, section Cable reel.


1

Table of content 5 Steering

3

5.2 Power assisted brake system 5.2.1 Component position

5 5

5.2.2 Filling / Changing planetary gear oil

5

5.2.3 Checking the wheel alignment

6

5.2.4 Lubrication points

8


2


5 Steering – Wheel turning sensors

5

3

Steering

General The wheel turning is performed by an electric motor without sepa‐ rate wheel position locking mechanisms. Multiple steering modes, controlled from the cabin: • • • •

normal container mode 90° turning of wheels wheels in parking position carousel drive around RTG’s centre

Wheel turning sensors Gantry travelling is possible only if PLC gets correct signal from steering sensors. If correct position doesn’t come during set time, Fault message appears in operator’s display.

A

B

Steering modes:

C

A) Traverse 0° (Normal travelling mode) B) Carousel ~23° (turning around RTG’s center point) C) Longitudinal 90° (Cross-travel mode)

FRONT SILL BEAM

A B

C

S121A

Limit switch A

Corner 1

S121B

Limit switch B

Corner 1

S121C

Limit switch C

Corner 1

S122A

Limit switch A

Corner 2

S122B

Limit switch B

Corner 2

S122C

Limit switch C

Corner 2


5 Steering – Cat-whiskers

4

REAR SILL BEAM S223A

Limit switch A

Corner 3

S223B

Limit switch B

Corner 3

S223C

Limit switch C

Corner 3

S224A

Limit switch A

Corner 4

S224B

Limit switch B

Corner 4

S224C

Limit switch C

Corner 4

Cat-whiskers Cat-whiskers (1) are located in front of side frames. Lubricate cat-whiskers by using aerosol spray.Lubrication interval 2000 hours or at least 4 Months. Turn cat-whiskers left and right a couple of times.

1

1


5 Steering – 5.2 Power assisted brake system

5.2

Power assisted brake system

5.2.1

Component position

5

Steering

1

3

2

4

5

1. 2. 3. 4. 5.

Steering motor Planetary gear Oil tank Inductive switches Tie rod

5.2.2

Filling / Changing planetary gear oil

Instructions 1 2

2

3

1

3 4

Unscrew the plug (1). Fill the gearbox with oil through the filling hole (2) until it flows out from the hole (1). Plug the hole (1). Complete the oil filling up to the proper oil level. Check the oil level through the glass eye (3).

Changing oil Remove the planetary gear in order to drain oil. The drain plug is at the bottom of the gear.



6

5.2.3

Checking the wheel alignment

Instructions

E

A 6

6

B

A

C

7

D

E

10

10

8

5

4

8

9

2

11

3 11

1 1

22mm D-D

D1


La

Lb

Lc

Ld

Ld

D

Lc

Lb

C La

790

B


7

NOTE These instructions apply to both 8- and 16-wheeled RTGs. Before checking the wheel alignment, drive the crane gantry direc‐ tion several times. Perform the wheel alignment on two supports (10) by following steps 1-11. You need two alignment pins (6) and a wire (7). 1 2 3 4 5 6 7

8 9

10 11

12 13

Unscrew the wheel nuts at the wheel hub’s centreline level (position A). Fasten the alignment pins (7) and the wire (8) into positions B and C. Remove paint from the head of the end stop screws (1) (4 pieces). Turn the outer wheels so that La – Lb =±1mm. Screw the nuts of the outer end stop screws (1) (under the bogie beam) onto the fork’s support (see view D1). Tighten the nuts of the outer end stop screws. Check that the inner inductive switch (2) is halfway (9mm) over the steering plate (3), if not, loosen the screws (5) in order to move the switch bracket (4). Align the inner wheels by adjusting the length of the tie rod (8) so that Lc – Ld = ±1mm. Pre-adjust the inner end stop screws (1) to a distance of 22 mm from the end of the bogie beam’s bottom plate (see sec‐ tion view D-D). Turn the wheels (90º) electrically against the end of the pread‐ justed end stop screw. Check that the inner inductive switch (2) is halfway (9mm) over the steering plate (3). If not, you have to adjust the end stop screw and turn the wheels electrically again until a 90° position is reached. You can also check this by looking from the top (see section view E). The back plate (9) of the inductive switch bracket should be at the same position as the groove (11) on the outer edge of the steering plates (see the arrow). Tighten the nuts of the inner end stop screws. Remove the alignment pins and the wire from positions B and C. Screw the wheel nuts back on.



8

5.2.4

Lubrication points

Steering linkage

Bogie

1

A-A

B-B B A

A B

NOTE Unscrew the plug (1) for the duration of lubrication


1

Table of content 6 Suspension

3

6.3 Tyres and rims 6.3.1 Tyre pressures

3 3

6.3.2 Checking a rim

4

6.3.3 Tightening torques of the wheel nuts

6

6.3.4 Cleaning wheel hub and rim before installation

7

6.3.5 Tyre pressure monitoring system (option)

8


2


6 Suspension – 6.3 Tyres and rims

6

Suspension

6.3

Tyres and rims

6.3.1

Tyre pressures

3

Safety

DANGER >3m

The machine must not be able to move during maintenance. Before lifting and changing the wheels, always place wheel chocks in front of the jack and the machine wheels. Always deflate the tyres to 1 bar or less before handling them. Com‐ ponents of a wheel under pressure can be thrown off when the wheel is handled. Do not deflate a tyre through the valve if the tyre or rim is damaged. A damaged tyre can explode. Never stand directly in front of a tyre that is being inflated or defla‐ ted. Components of a wheel can be thrown off when the tyre pres‐ sure is changed. Never install damaged tyres or rims. Repairing rims by welding is prohibited. The machine is not to be used if any of the tyres is deflated.

WARNING The tyre installation work may only be performed by trained person‐ nel using appropriate tools. Suddenly deflating tyres can cause severe injuries during installation.


4


CAUTION The mounting nuts of the changed wheels must be retightened after 4-5 hours of operation. Always follow the tyre manufacturer´s instructions or similar instruc‐ tions when changing the tyres. Never use a steel hammer for installing or removing rim components. Use alloy or plastic hammers. Keep the tyre pressures at the specified level. Improperly inflated tyres decrease stability and machine capacity. Remove any items which can cut the tyre, for example, splinters of glass or wood and metal chips, from the tyres. Pay attention to abnormal tyre wear which can be caused by a fault, such as brakes that operate unevenly. Repair any faults immediately.

IMPORTANT Use a protective screen, hearing protection and safety glasses. Tyre pressure recommendation The tyre pressure is checked when the tyre is cold. Keep the tyre pressures at the specified level by utilizing the air compressor and accessories supplied with the RTG cranes. The tyre pressures, see Chapter F Technical data

Fig. : Protective screen 6.3.1.1

Air compressor (option)

Instructions For further information regarding the air compressor, please refer to the appendix section of this manual for complete air compressor manual.

6.3.2

Checking a rim

General

DANGER Before starting to work on a tyre, the tyre must always be deflated entirely or to about 1 bar (15 psi).



5

CAUTION Use appropriate lifting equipment for handling the removed compo‐ nents.

IMPORTANT It is recommended that any inspection work on the rims including non-destructive testing (NDT) methods be performed by an appropri‐ ate expert. Hairline cracks or larger cracks may be formed on the rims over a long period of time. We recommend checking the rims annually with the magnetic particle testing method. The inspection can be performed on one rim at a time in conjunction with other tyre service procedures. The checked rims are easy to identify if they are marked with, for example, a colour that is changed each year. Component position Rim structure

2

1

3 5 4 6 7

1. 2. 3. 4. 5. 6. 7. 8. 9.

8 9

Flange Lock ring driver Lock ring Gutter band O-ring Bead seat band Center band Back band Rimbase and disc

Alternative 1 2

1

3 5

4

6 7

8

9

Alternative 2



6

Checking a rim

4

1 2 3 4

8

5 6

Deflate the tyre. Remove the wheel. Remove the tyre from the rim, and disassemble the rim; see paragraph Rim structure. Remove loose items 1 and 6. Clean the areas of the rim that are marked with a dash line in the figure, removing all paint. Check the marked areas with magnetic particles. If there are no cracks, accept the rim for use. If there are cracks, grind the cracked sections until they are smooth, do not grind deeper than 0.5 mm. Perform a pene‐ trant test with a solvent-based penetrant liquid. If there are no cracks, accept the rim for use.

7 8

If there are cracks, discard the rim. Protect the rim from rust by, for example, painting it. Reassemble the rim, and install the wheel.

NOTE Ensure that the rim components are properly in place. 9

Mark the rim, and record the procedures in the service log.

6.3.3

Tightening torques of the wheel nuts

Instructions Check the condition of the threads of the wheel mounting scews and nuts when installing the wheel. The threads must be intact and clean. Lubricate the threads lightly.

12

1

Use the right order when tightening wheel nuts. Tightening order for 12 and 20 nut wheels are shown in the illustrations.

5

Check tightening torques from Chapter F Technical data.

9

8

3

4 7

10 6

2 11

CAUTION If any of the bolts are broken, all bolts of that joint must be replaced.

NOTE Fig. : Tightening order for wheels with 12 nuts

Check the wheel nuts visually every day and the tightening torque every 500 hours.



16 8

24 1 9

17

5 13

20 12 4 22 14 6

7

21 3 11 19 7 18 10 2 23 15

Fig. : Tightening order for wheels with 20 nuts

6.3.4

Cleaning wheel hub and rim before installation

General All excessive grease and other impurities must be cleaned from the contact surfaces of the wheel hub and rim before installing the wheel. Use grease removing chemical, for example, white spirit. Cleaning a wheel rim Clean both sides of a rim on contact surfaces indicated in the figure. The contact surfaces should only have primer paint on the surface.

Cleaning a wheel hub Clean a wheel hub on contact surface indicated in the figure. Instruction applies to both driving and running wheel.



8

6.3.5

Tyre pressure monitoring system (option)

Description

WARNING The system does not prevent low tyre pressure, it only alerts of a low tyre pressure. The system does not prevent tyre or wheel overload. Overload‐ ing any tyre is extremely dangerous and can cause failure of suspension components, not just tires. Tyres can fail for other reasons besides low pressure or over‐ loading. Always be on the alert for other tyre problems as indica‐ ted by unusual noises, vibration, uneven tread wear or bulges on the tire.

• •

•

The system monitors the pressure in tyres via electronic sensors that read pressures and transmit a Radio Frequency (RF) signal to a monitor. The sensors read the tyre pressure in every seven seconds and send an updated pressure reading every five minutes to the monitor in the cabin. Monitor modes Normal mode •

•

The Vehicle LEDs next to the “Tractor display” and the trailer LED(s), flashes every four seconds either green for OK or red for alarm. The display remains blank. Program mode The program mode is used for programming the sensors to show data on the monitor. The selected vehicle LED flashes on/off every second. For any wheel position with a sensor pro‐ grammed, the "Tyre location selected" LED blinks and the dis‐ play shows three dashes ("- - -"). Nonprogrammed locations flashes when selected and scrolls a “No sensor" -message.

1

3

4

Button functions

2

5 1. 2. 3. 4. 5. 6.

6

Vehicle selection LEDs SEL button SEL button PROG button Sensor low-battery indicator UP & DOWN buttons


6 Suspension – 6.3 Tyres and rims •

9

SET button (3) When in Normal mode, pushing and holding the SET button lights up all tyre locations that have been programmed.

•

When in Program mode, pushing the SET button exits the Pro‐ gram mode. PROG button (4) Hold the PROG button (approximately for five seconds) until the LED for the selected group blinks ‘off’ as part of the on/off alternations denoting Program mode. Deleting a single sensor/location: With a tyre location selected, hold the PROG button for approximately. 10 seconds to delete a single sensor location. To delete all sensor locations: Hold the PROG button for 30 seconds. After five seconds, the Group LED begins to flash; hold for another five seconds and “DEL” appears on the moni‐ tor.

NOTE If the selected group LED begins to flash after being in Normal mode for approximately five seconds, continue to hold the PROG button until the group LED returns to solid and "DEL" appears on the display (approximately 10 seconds). The selected tyre location is deleted and the next wheel location flashes after the PROG button is released. •

UP & DOWN buttons (6)

•

In both Normal and Program mode, push the UP button to rotate the tyre locations clockwise. Push the DOWN button to rotate the selected tyre location counterclockwise. SEL button (2) The SEL button displays the pressures on the unit that is lit solid the remaining groups are flashing).

6.3.5.1

Setting upper pressure alerts

Instructions 1 2

3 4

5 6

Unplug the power cord from the monitor (the mini-USB con‐ nector). While holding down the UP button, plug the power cord back into the monitor. A new alert level percentage is displayed on the screen. Release the UP button. If the monitor displays the upper alert pressure you desire, continue to step 5. If it is not the upper alert you desire, repeat steps 1 and 2 until you see the desired alert level. The high alert function can be turned OFF by repeating the steps 1 and 2 after the 45% level is reached. To turn the high alert function back ON, repeat the steps 1 and 2 to get the 10% alert level.


10

6 Suspension – 6.3 Tyres and rims 6.3.5.2

Sensor alerts

Description •

FIRST STAGE LOW PRESSURE ALERT Alerts at 12.5% pressure loss from the initial pressure at instal‐ lation. The first alert level gives an audible beep, flashes the tyre location and displays the low pressure until the low pres‐ sure is corrected the SET button is pressed putting the monitor into reminder mode, or the monitor is unplugged.

•

If no button is pressed to mute the system continues to alert. SECOND STAGE LOW PRESSURE ALERT Alerts at 25% pressure loss from the initial pressure at installa‐ tion with an audible beep. Displays the low pressure and flashes the tyre location.

•

If no button is pressed to mute the system, the system contin‐ ues to alert until the pressure is corrected. REMINDER MODE

•

To mute the audible alert, set into reminder mode by pressing the SET button. The system gives a periodical audible alert. “SIGNAL CHECK IN” FEATURE

•

Sensors send “check-in” signal bursts regularly. If a signal is repeatedly lost, the monitor lights the selected wheel location with a solid light (no beeping alert except when the location is selected – it displays dashes “_ _ _” ). MULTIPLE LOW PRESSURE ALERTS

•

The monitor flashes all locations with low pressures. When a tyre location is selected, the system flashes the pressure and position of the selected tyre location and gives an audible alert. HIGH PRESSURE ALERTS (VARIABLE) Alerts at 25% high pressure. The level of the alert can be set by end user from 10%, 15%, 19%, 24%, 28%, 33%, 40% and 45% over the set level. High alert can be turned OFF.

6.3.5.3

Testing signal strength in diagnostic mode

Sensor packet counts 1

2 3

4

Set the monitor into the Program mode by holding the PROG button (for approximately five seconds). Release when the Tractor or Trailer light begins flashing. Use the UP or DOWN buttons to select a tyre location. The monitor displays three dashes (---). Hold the SET button down until a number appears on the dis‐ play (for approximately five seconds), then release the button. The display goes blank when the SET button is released and the unit changes to diagnostic display mode. Scroll to tyre locations with UP & DOWN buttons. The number displayed for each location is the current transmission count for that selected tyre (00 to 255).



11

NOTE When in diagnostic mode, the Program mode and delete functions are disabled. Signal strength testing 1

Press and hold the PROG button to change the diagnostic display contents from the packet counts to the background “signal” level. While holding the PROG button, three digits appears. The first two digits indicate the RF ‘noise level’ the monitor is experi‐ encing at that time, and the last digit is always "A" meaning Ambient Temperature. The RF noise level tells how much RF interference is present. Levels over 8 makes receiving sensor packets more difficult. The lower the number, the less interfer‐ ence. When the PROG button is released, the display continues showing the signal level status of the selected sensor. In the signal level status display mode, the first two digits give an indication of the RF signal strength level above the RF level - measured during the latest packet. The last digit is the temperature code received from the sensor.

2

Indication

Sensor melting range

0

-40C

1

-20C

2

0C

3

20C

4

40C

5

60C

6

80C

7

100C

Signal strength of 1 or 2 is marginal reception; some signals will not be received. Signal strength above 4 is good. Average signal strength is in 4 to 6 range. 3

To toggle between packet counts and signal level, press the PROG button repeatedly. Toggle sequence is:


12

6 Suspension – 6.3 Tyres and rims a) b) c)

d) e)

Packet count (last decimal point). Background noise level while PROG held. Sensor signal strength (no decimal point) or repeater sig‐ nal strength (second decimal point) depending which was the last signal to be received for that programmed sensor. Background noise level while PROG held. Cycle repeats.

NOTE Pressing the SET button at any time cancels the diagnostic mode and blanks the display, returning the monitor to normal operation and dis‐ play. Receiving an alarm packet from a sensor also cancels the diag‐ nostic mode. 6.3.5.4

Checking the tyre pressures manually

Instructions 1

Remove the sensor.

NOTE The monitor shows "00" for that sensor and gives an audible alert. 2

Check the pressure, and inflate if necessary.

NOTE To reset a sensor´s baseline pressure, remove the sensor for 60 sec‐ onds, then reinstall. Removing and replacing a sensor on the valve stem after driving can result in "false" alerts. Allow tyres to cool to ambient temperature before installing sensors. If it is not possible to wait for the tyre to cool, remove the sensor when the tyre is warm, wait 60 seconds and screw back on. 6.3.5.5

Muting the audible alert

Instructions 1

Press the SET button after the alert sounds. This puts the monitor alert in "reminder" mode. An “alert” beep will continue periodically as a reminder of a low-pressure situation.

6.3.5.6

Removing sensors to rotate or replace tyres

Description When the sensors are installed, they are programmed to a specific tyre position. If rotating tyres or installing new tires or if you have to remove the sensors, do one of the following:



13

Marking sensors By marking the sensors, you eliminate the need to reprogram the sensor to the monitor. 1 2

Mark each sensor to identify its wheel location. When putting the sensors back onto the valve stem, screw the sensors back onto the sensor’s original wheel location.

Deleting the sensors 1 2

Delete each sensor from the monitor. When reinstalling sensors, reprogram them.

To delete a sensor or all sensors in a group, see section Button functions.


14



1

Table of content 7 Load handling

3

7.2 Lifting/lowering 7.2.1 Component position

3 12

7.2.2 Hoist ropes

17

7.2.3 Replacing hoist ropes using the mini-hoist

19

7.2.4 Replacing the hoist ropes using the service lift

29

7.2.5 Performing the trim maintenance (option)

37

7.2.6 Checking the tightness of fixing bolts of the hoist equipment

39

7.2.7 Alignment of the hoist machinery

40

7.2.8 Load cell calibration using the touch panel (if E-One2)

43

7.2.9 Lubrication points 7.4 Side movement 7.4.1 Description

44 46 46

7.4.2 Component position

55

7.4.3 Adjustment of the trolley chains

58

7.4.4 Installation of the skew pulling device

59

7.4.5 Removing the skew motor

60

7.4.6 Jacking and wheel change of trolley

64

7.4.7 Checking the tightness of fixing bolts of the trolley

65

7.4.8 Changing the lubrication oil of the hoist, trolley and skew gears

66

7.4.9 Lubrication points 7.9 Load carrying Bromma 7.9.1 Inspection of headblock (if using) twistlocks

68 73 74

7.9.2 Spreader stabilizer 7.9.3 Spreader cable

75 80

7.9.4 Changing the spreader cable

81

7.9.5 Load sensing system (option)

90

7.9.6 Lift hook (option)

90


2


7 Load handling – 7.2 Lifting/lowering

7

Load handling

7.2

Lifting/lowering

3

Description General Hoist machinery is equipped with disc-brakes that prevent move‐ ment when engine is not running or hoisting / lowering command is not active. Disc-brakes are spring-loaded and land immediately if the control circuit is broken. An electro-hydraulic thrusters open the brakes. The brakes have a manual release lever that enables lower‐ ing when normal lowering is not possible. Hoist gear is a three stage reduction gear mounted on the hoist drum shaft with a coupling. Hoist drum operates four separate ropes. Rope ends are fixed to the hoist drum by clamps. Driving speed is adjusted by the hoist joystick located at the opera‐ tor’s cabin; Inverter is adjusting the speed of the motor on the basis of joystick position. When the joystick is moved, the hoist brake opens. The brake stays open until the motor speed goes back to zero. Then the brake closes. During lowering, the hoist motor acts as an electrical brake. The command to brake is triggered when the motor speed exceeds the setpoint speed or the joystick returns the neutral position. Overspeed supervising is done by an absolute encoder that is con‐ nected to the hoist drum. In some machines the overspeed protec‐ tion is done by “the fail-safe overspeed" -switch. PLC-system monitors the hoist position by an absolute-encoder. When closing the end-stop positions, PLC starts automatically slow‐ down sequence according to PLC-program parameters. If the hoist position is wrong and there is a possibility that headblock / spreader rises too high, the overtravel switch activates and closes the hoist brake immediately. The hoist is guided by a smart slowdown system that controls the speed of the hoisting or lowering when closing to the end stop limit. The hoisting or lowering movement is stopped automatically at the end stop limit. Hoisting is limited with an overtravel limit that protects the hoist machinery from damage in case of PLC malfunction. In case of overtravel, the emergency stop is activated and the hoisting is stop‐ ped immediately. When the "emergency stop" -fault is triggered or the height position of the spreader is lost, the hoist system is synchronized by lifting the spreader to the overtravel limit switch.



4

1 2 3 4

1.

Overtravel limit up (hardware)

2.

Stops hoisting motion immediately and the Crane Off state is initiated. Hoist movement is possible only with bypass function. End stop limit up (software)

3.

Stops hoisting movement. Slowdown checkpoint up (software)

4.

PLC checks the hoisting speed at the checkpoint. If the speed is too high for controlled slowdown, the PLC executes an emer‐ gency stop. Slowdown start point up (software)

5.

Slowdown ramp begins. Location of slowdown start point var‐ ies depending on hoisting speed. Slowdown start point down (software)

6.

Slowdown ramp begins. Location of slowdown start point var‐ ies depending on lowering speed. End stop limit down (software)

5 6

Fig. : Hoist limits

Stops hoisting movement.



5

Hoist position, speed curves and limits hw = hardware limit sw = software limit

1

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

2 3

10

4

overtravel up, synchronization. point (hw) end stop up (sw) slowdown check up (sw) slowdown up (sw) slowdown down (sw) end stop down (sw) ground level max speed speed curve position curve

9

5

8 6 7

52

Diesel generator power supply Hoist movement consists of AC-Generator, rectifier, inverter and electric hoist motor. The system is powered by an AC-generator that is run by a diesel engine. Re-generative power from the motor is fed to the DC-link, where the braking units feed all excess energy to the braking resistors that transfer the braking energy into heat.

Zero emission power supply (option) Hoist movement consists of rectifier, inverter and electric hoist motor. The system is powered by external power source through a cable. The crane is equipped with medium voltage transformer if the power supply voltage is more than 1 kV.


7 Load handling – 7.2 Lifting/lowering Re-generative power from the motor is fed to the DC-link where the Active Interface Module (AIM) feeds all excess energy to the elec‐ tricity distribution network.

Function description of hoist

200-315kW

6




Pos

Function

1

The diesel engine generates the power required by the ACgenerator.

2

The AC-generator (G01) produces electric power to the system.

~300 – 425 VAC, 30 – 60Hz

3

Main circuit breaker (F01) protects the system from overload and short-circuit currents.

~300 – 425 VAC, 30 – 60Hz

4

Auxiliary inverter converts electric power to auxiliary loads like air conditioning, lightning, etc.

~400 – 440 VAC, 50 – 60Hz

5

Main fuses (F2) protect the generator inverter,generator inverter from overload.

~300 – 425 VAC, 30 – 60Hz

6

Generator inverter, (U5) converts the alternating current into direct current for the direct current intermediate circuit. (DC link)

~300 – 425 VAC /~600 – 625 VDC

7

Inverter (U1) receives electric power from the DC link and converts the DC power into AC power operating on adjustable frequency.

~600 – 625 VDC / 0 – 400 VAC, 0 – 92Hz

8

the hoist joystick (S731) sends a setpoint signal to the inverter via Profibus.

Joystick – PLC :24VDCPLC – inverter: Profibus

9

Brake (M603) opens when the inverter starts to control the motor and the motor is producing torque.

PLC – Brake Contactor 24VDC,Brake Contactor – Brake 400 VAC, 50 – 60Hz

10

The inverter controls the direction of rotation and the speed of the hoist motor (M601).

~ 0-400 VAC, 0 – 92Hz

11

PLC monitors the overload by inductive switches (S612-S615) or

Inductive switches - PLC

by load cells (B902, B903) 50 ton rated capacity crane. 12

Signal description

with

PLC monitors the temperature of the hoist motor with temperature sensors.



7

Reference


8

Pos

Function

Signal description

13

PLC monitors the speed of the motor with the pulse encoder (B601) on the motor.


15

PLC monitors the position of the spreader with the absolut-encoder (B603) attached to the hoist drum.

Absolute-encoder – PLC: Profibus

16

PLC monitors the overtravel of the hoist with an overtravel switch (S603).

Overtravel switch – PLC : 24VDC

17

When braking, the hoist motor is acting as an electrical brake. When the hoist joystick returns to the neutral position, the hoist motor starts to brake.

Joystick – PLC : 24VDC PLC – inverter: Profibus

18

Re-generative power produced by inverter goes thru DC link to braking units (A1 - A2)

~670 VDC

19

Braking units are sending all excess energy to braking resistors (R91 – R92), which are transferring braking energy to heat.

~670 VDC

20

When motor rotation speed is zero (motor stopped), the brake (M603) closes.

PLC – Brake contactor 24VDC, Brake contactor – Brake 400 VAC, 50 – 60Hz


Reference


9

Function description of hoist (zero emission power supply) PLC

PLC

12 9, 18

17 16

1, 20 540 - 600 VDC

7 ~

2

19 3

6

8

~

5

4

400 - 440 VAC

11

M~

°C

3

13 10, 21

14

PG

15

n




10

Pos

Function

Signal description

1

Electrical power is supplied from an external power source through a cable.


2

Electrical power is led through slip ring box of the cable ree (X160).


3

Medium voltage transformer transforms the supply voltage into a lower voltage. The transformer is applicable only when the power supply from an external power source of over 1 kV.


4


400 – 440 VAC, 50 – 60Hz

5

Main supply contactor (K50) connects the external power supply to the RTG electrical system.

400 – 440 VAC, 50 – 60Hz

6


400 – 440 VAC, 50 – 60Hz

7

Rectifier (U5) converts alternating current into direct current for the direct current intermediate circuit. (DC-link).

400 – 440 VAC / 540 – 600 VDC

8

Inverter (U1) receives the electric power from the DC-link and converts the DC power into AC power operating on adjustable frequency.

540 – 600 VDC / 400 – 440 VAC, 0 – 51 Hz

9

Hoist joystick (S731) sends a setpoint signal to the inverter via Profibus.


10

Brake (M603) opens when the inverter starts to control the motor and the motor is producing torque.

PLC – Brake Contactor: 24 VDC Brake Contactor – Brake: 400 VAC, 50 – 60Hz

11

Inverter controls the direction of rotation and the speed of the hoist motor (M601).

~ 400 VAC, 0 – 51 Hz

12

PLC monitors the overload by inductive switches (S612-S615).

Inductive switches - PLC


Reference


Pos

Function

Signal description

13

PLC monitors the temperature of the hoist motor with temperature sensors.


14



15

PLC monitors the overspeed of the hoist motor with an overspeed switch (S601).

Overspeed switch – PLC: 24 VDC

16

PLC monitors the position of the spreader with the absolut-encoder (B603) attached to the hoist drum.

Absolute-encoder – PLC: Profibus

17

PLC monitors the overtravel of the hoist with an overtravel switch (S603).

Overtravel switch – PLC: 24 VDC

18

When braking, the hoist motor is acting as an electrical brake. When the hoist joystick returns to the neutral position, the hoist motor starts to brake.


19

Regenerative energy generated during braking is fed via a DC-link to the Active Interface Module (AIM) (U7).

~680 VDC

20

AIM unit feeds all excess energy to the electricity distribution network.

21

When motor rotation speed is zero (motor stopped), the brake (M603) closes.

PLC – Brake contactor: 24 VDC Brake contactor – Brake: 400 VAC, 50 – 60Hz


11

Reference


12

7.2.1

Component position

Hoist equipment

4

5

2 1 6

1. 2. 3. 4. 5. 6.

Hoist motor Coupling Hoist brake Hoist gear Hoist drum Emergency hoist brake Trim (option)

2 1 1. 2.

Trim motor Trim gear


3


13

Hoist overtravel switch The overtravel is protected by an overtravel switch that closes the hoist brake. The crane goes off if the spreader is too high.

7.2.1.1

Overload / eccentric overload protection sensors on skew trollies

Instructions

IMPORTANT Before the adjustments of the sensors, check the lifting capacity of the machine. See chapter F Technical data 1 2

Hoist a container with a 10 % overload. If the hoist overload fault appears in the cabin display, use the "Prevent Bypass" -switch in the cabin and lower the container.

NOTE The torque measurement of the hoist inverter is used for calculating the load. Overload is detected on PLC by comparing the calculated value to a 3 % limit value. The weighing result of the container is not displayed in the cabin, because the overload sensors stop the weighing of the container when there is overload.


14


Faults in cabin display Fault

Indication

F-7

Hoist overload

F-25

Hoist eccentric load

3

To adjust the overload sensors, move the sensors in the required direction (up/down) just enough to trigger the "hoist overload" -fault (the sensor goes OFF). Adjust the eccentric overload sensors first at the same height than the overload sensors and then lower the sensors four (4) millimeters.

4

NOTE Only in machines with hoist capacity of 35 tons, 40 tons or 41 tons. 5

Adjust the eccentric overload sensors first at the same height than the overload sensors and then lower the sensors five (5) millimeters.

NOTE Only in machines with hoist capacity of 45 tons.

Overload sensors Capacity

Test load (adjusting overload 10 %)

Setting

35 t

ca. 38 t

Setting at 19 t/side

40 t

ca. 44 t


41 t

ca. 45 t

Setting at 22.5 t/side

45 t

ca. 50 t


Almost overload sensors (option) The adjustment height depends on the container weight for which you want the "Almost overload" -fault to be triggered.



15

Almost overload sensors Capacity

Test load (adjusting underload 5 %)

Setting

35 t

ca. 33.5 t


40 t

ca. 38 t


41 t

ca. 39 t


45 t

ca. 43 t


S661 (2)

Left side

Overload

S662 (1)

Left side

Eccentric

S663 (2)

Right side

Overload

S664 (1)

Right side

Eccentric

S665 (3)

Left side

Almost overload

S666 (3)

Right side

Almost overload

Load sensors

3 1 2



16

Load cell sensors (option) The machine with a rated hoist capacity of 50 t or more is equipped with load cell sensors that detect overload. The load cells are moun‐ ted on the axles of two sheaves out of four.

Fig. : Load cells on the headblock Slack rope sensors

1 1

The indicator switches (1) detect a hanging slack rope. They are located next to each intermediate sheave.

1 1

1



7.2.2

17

Hoist ropes

Trim sensors (option)

CAUTION Before you adjust the sensors, push the Crane Off switch on the touch panel. This will prevent the trim movements during the adjust‐ ment. After the adjustment, push the Crane On switch on the touch panel.

3 1

1. 2. 3.

2

The space between a sensor and the plate is 3 mm.

S617, Trim down S616, Trim up S634, Trim end stop 7.2.2.1

Checking the condition of the hoist ropes

General

IMPORTANT Any changes noticed in the condition of the hoist ropes must be reported to a supervisor or service personnel responsible for servic‐ ing the machine. The condition of the hoist ropes is one of the key factors affecting the reliability and safety of lifting devices. The hoist ropes must be visually checked daily for any damage and deformations. Pay special attention to the point at which the rope meets the pulley when the spreader is at the container transporta‐ tion height. Pay particular attention to the condition and operation of the ropes during the first 50 hours of operation after replacing the cable. Most deformations occur during this time. Rope structure The hoist rope is a steel wire.



18

A)

B)

1

2

3

General structure 1. Rope core 2. Cord 3. Strand core 4. Rope strand Cross-section

4

When to discard

CAUTION If the rope damage was caused by a malfunction of the lifting device, the device must be repaired before replacing the rope.

CAUTION The rope must be discarded if the number of broken cords is more than 14 on a section of 132 mm or 29 on a section of 660 mm. These limits are based on the ISO 4309 and DIN 15020 standards. If broken cords are found but there are fewer of them than this, the ropes must be checked every 500 hours of operation.

Fig. : Examples of wires that must be discarded immediately.



19

The operational safety of a hoist rope is determined by the following • • • • • • • • • • •

Number and type of wire fractures Wire fractures near terminals Many wire fractures within a short section Accumulation of wire fractures Broken strands Reduced diameter caused by a damaged core Reduced elasticity Internal and external wear Corrosion Deformations Damage caused by heat or electricity

7.2.3

Replacing hoist ropes using the mini-hoist

General These instructions apply to machines both with a trim and without it. Preparatory procedures Lower the spreader on planks or some other stand on the ground so that the weight is not on the twist locks or flippers. Remove the rain covers from the top of the hoisting drum and idlers. Place the covers on the service platform in the middle of the trolley.

CAUTION Always use a safety harness when working on the crane outside the safety rails. 7.2.3.1

Detaching the rope-ends of old ropes

Detaching the ropes that go to the hoisting drum through the idlers 1 2 3 4 5 6 7

A

Use a lifting sling to fasten the top of the mini-hoist to the rail (A) next to the idler. Attach a hook to the mini-lift wire rope. Use a rope lock and a lifting sling to fasten the hoist hook to the hoist rope to the point (B). Lift the rope with the hoist. The rope-end on the drum becomes loose. Remove all fasteners holding the rope-end on the hoisting drum. Lower the rope to the ground with the mini-hoist. Repeat steps 1-6 to the other rope coming to the drum through the idler.

Fig. : Fastening points for the top of the mini-hoist (A)



20

B

B

A

A B

A-A

Fig. : Fastening points for mini-hoist hook (B) Detaching the ropes that go straight to the drum 1

B

2 3 4 5 6 7

Use a lifting sling to fasten the top of the mini-hoist to the rail (B) behind the hoisting drum. Attach a hook to the mini-lift wire rope. Use a rope lock and a lifting sling to fasten the hoist hook to the hoist rope to point (C). Lift the rope with the hoist. The rope-end on the drum becomes loose. Remove all fasteners holding the rope-end on the hoisting drum. Lower the rope to the ground with the mini-hoist. Repeat steps 1-6 to the other rope coming straight to the drum.

Fig. : Fastening points for and the top of the mini hoist (B)



21

Fig. : Fastening points for mini-hoist hook (C) Detaching ropes from the skew To detach the rope fastened to the skew, remove the rope length adjustment screw from the skew. Remove also the pocket and hoist rope-end.

1 5 2 4 3 6 7

1. 2. 3. 4. 5. 6. 7.

idler adjustment screw installation bar shackle mini-hoist wire mounting nut skew



22

1

Fasten the top of the mini-hoist with a lifting sling to the rail (H) next to the idler (1). Remove the mini-hoist hook. Screw the installation bar (3) to the end of the adjustment screw (2) on the skew (7). Fasten the bar to the mini-hoist wire (5) with the shackle (4). Lift the adjustment screw (2) and rope slightly with the minihoist. Open the locking of the mounting nut (6) and screw it open. Remove the nut. Lower the rope to the ground with the mini-hoist. Repeat steps 1-7 to the other rope fastened to the skew and to both ropes fastened to the other skew.

2 3 4 5 6 7 8

H

Fig. : Fastening points for the top of the mini-hoist (H)

NOTE If the machine is equipped with a trim, perform also the following steps.

A

9

B

Put the trim locking pin through the trim wheel and to the point (B). This way the trim does not move during the installation.

CAUTION If the locking pin is not used, the trim may move and cause injury. After the replacement of the ropes, the locking pin must be detached from the center hole. Otherwise it is possible to damage the trim motor by driving into the locking pin. A. B.

locking pin storage locking hole 10 11

Tie the top end of the mini-hoist with a lifting sling to the posi‐ tion (D). Attach a hook to the mini-lift wire rope.

D

Fig. : Fastening points for the top of the mini hoist (D)


7 Load handling – 7.2 Lifting/lowering 12

13 14 15

E 16 17 18

23

Use a rope lock and a lifting sling to fasten the mini-hoist wire and hook to the hoist rope point (E). The fastening point is at the service platform level. Move the skew so that the mini-hoist wire rope is straight down. Slightly lift the hoist rope with the mini-hoist. When the rope on the trim is loose, remove the locking pin and the mounting bolt. Dismantle the pocket at the rope-end so that the rope can fit through the trim. Lower the rope to the ground with the mini-hoist. Repeat steps 9-17 to the other rope on the trim.

Fig. : Fastening points for mini-hoist hook (E) 7.2.3.2

Installing new ropes

Instructions

IMPORTANT Before you start installing the ropes, note that the ropes are not all the same length. The length of the hoist ropes varies depending on whether the ropes go straight to the drum or through an idler and whether the machine is equipped with a trim or not. Also the two ropes coming to the trim are of different length.

A B A

There are two types of hoist ropes. The lays of rope are different, the lay can be left- or right-handed. These different types are marked as follows: SZ = righthanded lay and ZS = left-handed lay. Keep the new ropes as clean as possible during the installation. It is easier to balance the spreader later if the pocket of each rope is placed at the same distance (A and B) from the rope-end.

A. B.

50 mm (2 in) 100 mm (4 in)

Check the diameter of the hoist ropes. The correct diameter can be found from the technical data. Make sure that the rope lengths and places for each rope are cor‐ rect. The correct lengths can be found from the technical data.

CAUTION When a hoist rope is pulled up from a reel on the ground, the reel must be rotated so that the rope does not become twisted. The twists can bend the rope so that it is damaged.



24

Fig. : Positions of the hoist ropes (1-4) Installing the rope-ends to the skew 1 2 3 4

Install the pocket at the end of a new rope on the ground and tighten it. Fasten the adjustment screw detached from the skew to the pocket. Fasten the top end of the mini-hoist to the trolley rail. Remove the mini-hoist hook.

Fig. : Installation bar coming through the skew 5

1 2

6 7

Lower the hoist wire rope end to the ground through the hole on the skew (5). Use the installation bar (2) and the shackle (3) to fasten the assembly prepared on the ground to the wire rope. Lift the adjustment screw (3) up through the skew hole.

3 4 5

Fig. : Mounting nut in its place 1. 2. 3. 4. 5.

shackle installation bar adjustment screw mounting nut skew



25

8

Make sure that the twist-prevention pin (8) goes to a slot on the adjustment screw (9) to prevent the hoist rope from twist‐ ing.

9

Thread the mounting nut (6) in its place on the adjustment screw and lock it. Check the mounting of the twist-prevention pin (8). There must be a spring washer (7) under the mounting nut (6), and some of the pin’s threads must be visible. Tighten with care if necessary. Repeat steps 1-10 to the other rope-ends that will be fastened to the skews.

Fig. : Threading the mounting nut in its place 8 7

6

10

11


9

12

Thread the rope end through the trim, pull it all the way to the ground and then install the pocket on the ground.

Fig. : The mounting of the twist-prevention pin. 6. 7. 8. 9.

NOTE

mounting nut washer twist-prevention pin adjustment screw (includes a slot for a pin)

The rope is installed to the trim with the same kind of pocket as to the skew. The fastener must not be fastened to the rope on the ground beforehand because then the rope would not fit to its place through the trim. 13 14

15 16 17

D 18

Fig. : Fastening points for the top of the mini hoist (D) 19 20 21

Tie the top end of the mini-hoist with a lifting sling to the posi‐ tion (D). Fasten the mini-hoist wire rope to the hoist rope with a shackle, rope lock and a lifting sling, leave 5 metres of the rope free on the rope-end. Lift the hoist rope with the mini-hoist. Thread the rope through the trim. Use a rope lock and a lifting sling to fasten an auxiliary rope to the end of the hoist rope that comes through the trim. Leave enough rope free after the fastening point to attach the pocket. Lock the other end of the hoist rope to a fixed object on the ground to prevent it from rising to the trim during the installa‐ tion. Detach the mini-hoist wire rope from the hoist rope. Use the auxiliary rope to pull the hoist rope-end to the ground. Install the pocket to the rope-end.


26


23 24 25

Pull the free end of the rope by hand so that the other ropeend and the pocket installed to it rise to the trim. At the same time, slow down with the auxiliary rope so that the rope-end does not rise to the trim too fast. When the pocket is in its place in the trim, put the mounting bolt and locking pin in their places. Detach the auxiliary rope. Repeat steps 12-24 to the other rope that will be on the trim.

Threading the ropes

Fig. : Rope lay-out Thread the ropes through the idlers of the spreader or the head‐ block. The idlers are on the headblock, if the machine has one. If there is no headblock on the machine, the idlers are on the spreader. Thread the ropes as shown in the figure.



27

Installing the rope-ends to the drum The rope installation method varies depending on whether the ropes come to the drum straight from the headblock or through the rope idlers.

A

1 2 3

B

A. B.

Fasten all the four rope-ends to the drum with one small fas‐ tener (B). Check the balance. Rotate the drum three rounds and then fasten the ropes per‐ manently with larger fasteners (A).

large fastener small fastener Installing the rope-ends that come straight to the drum Ropes that come straight to the drum are fastened with the fasten‐ ers in the middle of the drum. 1 Use a lifting sling to fasten the top of the mini-hoist to the rail behind the hoisting drum.. 2 Use a shackle, a rope lock and a lifting sling to fasten the min‐ ihoist wire rope on the ground to the hoist rope. Leave 1.5 metres of the rope-end free. 3 Lift the rope up to the drum. 4 Use a small fastener to fasten the end of the rope to the drum.

NOTE Do not tighten the first small single-rope-fastener too much. Avoid bending of bolt. 5 6

Detach the mini-hoist Repeat steps 1-5 to the other hoist rope that comes straight to the drum.

Installing the rope-ends that come through the idler to the drum Ropes that come through the idlers to the drum are fastened with the fasteners at the end of the drum. 1

Use a lifting sling to fasten the top of the mini-hoist to the rail behind the hoisting drum.



28

2 3

A

4

5 6

Attach a cable stocking (B) to the hoist rope-end (A). Attach the mini-hoist wire rope to the cable stocking with a shackle. Pull the rope with the mini-hoist through the idler to the drum. You must pull the rope slightly past the drum so that the cable stocking does not remain between the fasteners. Fasten the rope with a large fastener to the last fastening point on the drum. Detach the mini-hoist and cable stocking from the hoist ropeend.

B

A. B.

Hoist rope-end Cable stocking 7

Fasten the rope-end with a small fastener to the correct posi‐ tion on the drum (at this point the rope is bent so that it is upraised on the drum).

584 Nm A

NOTE Do not tighten the first small single-rope-fastener (A) too much. Avoid bending of bolt. 8 9

Fig. : Correct torque for double-rope-fastener

Remove the large fastener from the drum. The rope takes its correct place on the drum. Repeat steps 1-8 to the other rope that comes to the drum through the idler.

Balancing the spreader When the ropes are fastened with one small fastener, you can check if the spreader is balanced when lifted. All ropes must carry an equal amount of the load. If rough adjustment is needed (10 cm or more), the adjustment is done by moving the fastening point of the rope forward on the drum. Move the rope end with the minihoist the same way as before. Fine adjustment is done later with the rope length adjustment screws that are attached to the skews. Final fastening of the hoist rope-ends on the drum When the spreader is roughly balanced, the ropes can be fastened more permanently. Use a weight to make sure that the ropes are straight and tight on the drum. 1 2 3

Rotate the hoisting drum three rounds. When rotating the hoisting drum, make sure that the ropes are in line on the drum. Fasten the double-rope-fasteners to the correct torque (Tight‐ ening torque 584 Nm).

Procedures after the installation 1 2

Fine-adjust the spreader balance with the adjustment screws on the skews. Lubricate the ropes.



7.2.4

29

Replacing the hoist ropes using the service lift

General These instructions apply to the machines both with a trim and with‐ out it. Preparatory procedures

CAUTION Always use a safety harness when working on the machine outside the safety rails. 1 2 3

Lower the spreader on planks or some other stand on the ground so that the weight is not on the twist locks or flippers. Remove the rain covers from the top of the hoisting drum and idlers. Place the covers on the service platform in the middle of the trolley.

7.2.4.1

Detaching the rope-ends of old ropes

Detaching the ropes that go to the hoisting drum through the idlers

B

B

A

A B

A-A

1 2 3 4

Use a rope lock and a lifting sling to fasten the service lift chain to the hoist rope to the point (B). Lift the rope with the lift. The rope-end on the drum becomes loose. Remove all fasteners holding the rope-end on the hoisting drum and lower the rope to the ground with the service lift. Repeat steps 1-3 to the other rope that come to the drum through the idler.



30


A

B

5

Lock the trim with the locking pin (B) through the trim wheel. This way the trim does not move during the installation.

CAUTION If the locking pin is not used, the trim may move and cause injury.

WARNING A. B.

After the replacement of the ropes, the locking pin must be detached from the center hole. Otherwise it is possible to damage the trim motor by driving into the locking pin.

Locking pin storage Locking hole

A

6 7

Attach a hook to the end of the service lift chain. Thread the lift chain at a point (A) through the trolley next to the other trim rope.

A Fig. : Threading points for the lift chain (A)



9 10 11 12 13

31

Use a rope lock and a lifting sling to fasten the service lift chain to the hoist rope. A suitable fastening height is at the trim service platform level (D). Lift the hoist rope a few inches with the service lift. When the rope on the trim is loose, remove the locking pin and the mounting pin from the pocket. Dismantle the pocket at the rope-end so that the rope can fit through the trim. Lower the old rope to the ground with the service lift. Repeat steps 5-12 to the other rope on the trim.

D Fig. : fastening points for the lift hook (D) Detaching the ropes that go straight to the drum

C A

A C

A- A 1 2 3 4

Use a rope lock and a lifting sling to fasten the service lift chain to the hoist rope to the point (C). Lift the rope with the lift. The rope-end on the drum becomes loose. Remove all fasteners on the hoisting drum and lower the rope to the ground with the lift. Repeat steps 1-3 to the other rope coming straight to the drum.

Detaching the rope-ends fastened to the skew To detach the rope fastened to the skew, remove the adjustment screw of the rope length from the skew. The pocket and hoist ropeend are also removed.



32

1

6

1 2

3

4 5 6

4

7

5 1. 2. 3. 4. 5. 6.

2 3

Screw the installation bar (2) to the end of the adjusting screw (3) on the skew and lock it with the mounting nut (4). Remove the hook from the end of the service lift chain (6). Attach the service lift chain to the installation bar with the shackle (1). Lift the adjusting screw and rope slightly with the lift. Open the locking of the nut and screw it open. Lower the rope to the ground with the lift (the lift chain goes through the skew and the nut). Repeat steps 1-6 to the other rope fastened to the skew and to both ropes fastened to the other skew.

shackle installation bar adjusting screw mounting nut skew service lift chain 7.2.4.2

Installing new ropes

Instructions

NOTE Before you start installing the ropes, note that the ropes are not all the same length. The length of the hoist ropes varies depending on whether the ropes go straight to the drum or through an idler and whether the machine is equipped with a trim. Also the two ropes com‐ ing to the trim are of different length.

A B A

There are two types of hoist ropes. The lays of rope are different, the lay can be left- or right-handed. These different types are marked as follows: SZ = right-handed lay and ZS = left-handed lay. Keep the new ropes as clean as possible during the installation. It is easier to balance the spreader later if the pocket of each rope is placed at the same distance (A and B) from the rope-end.

A. B.

50 mm (2 in) 100 mm (4 in)

Check the diameter of the hoist ropes. The correct diameter can be found from the technical data. Make sure that the rope lengths and places for each rope are correct. The correct lengths can be found from the technical data.

CAUTION When a hoist rope is pulled up from a reel on the ground, the reel must be rotated so that the rope does not become twisted. The twists can bend the rope so that it is damaged.



33

Fig. : Positions of the hoist ropes (1-4) Installing the rope-ends to the skew 1

3 2

1

Install the pocket at the end of a new rope on the ground and tighten it. Fasten the adjustment screw (4) detached from the skew to the pocket. Remove the hook from the end of the chain. Lower the service lift chain to the ground through the hole on the skew and the mounting nut (1). (The nut cannot be instal‐ led later, it must be taken into consideration at this point.) Fasten the assembly prepared on the ground to the chain with the installation bar and the shackle Lift the adjustment screw (4) up through the skew hole and adjustment screw nut. When the rope is nearly up, it is impor‐ tant to check that the pin (3) goes to the slot on the adjust‐ ment screw (4). Thread the mounting nut (1) in its place on the adjustment screw (4) and lock it. Check the mounting of the twist-prevention pin. There must be a spring washer (2) under the mounting nut (1), and some of the pin’s threads (3) must be visible. Tighten with care if nec‐ essary. Repeat steps 1-8 to the other rope-ends that will be fastened to the skews.

2 3 4

5 6

4 7

Fig. : The mounting of the twist-prevention pin. 1. 2. 3. 4.

mounting nut washer twist-prevention pin adjustment screw (includes a slot for a pin)

8

9

NOTE If the machine is equipped with a trim, perform also the following steps. 10

Thread the rope end through the trim, pull it all the way to the ground and then install the pocket on the ground.

NOTE The rope is installed to the trim with the same kind of pocket as to the skew. The pocket must not be attached on the ground beforehand because then the rope would not fit to its place through the trim.



34

A

11 12 13 14 15

16

17 18 19

20

A Fig. : Chain lay-out (A)

21

Lower the service lift chain to the ground through a point (A). Use a rope lock and a lifting sling to fasten the lift chain to the hoist rope. Leave 5 metres of the rope free. Lift the hoist rope with the lift. Thread the rope through the trim. Use a rope lock and a lifting sling to fasten an auxiliary rope to the end of the hoist rope. Leave enough rope free after the fastening point to attach the pocket. Lock the other end of the hoist rope to a fixed object on the ground. This prevents it from rising to the trim during the installation of pocket on the other end. Detach the service lift chain from the hoist rope (keep the hoist rope in its place with the auxiliary rope). Pull the rope-end to the ground with the auxiliary rope and install the pocket to the rope-end. Pull the other end of the rope by hand so that the rope-end with the pocket attached to it rises to the trim. At the same time, slow down with the auxiliary rope so that the rope end does not rise to the trim too fast. When the pocket is in its place in the trim, put the mounting pin and locking pin in their places Repeat steps 10-20 to the other rope that is on the trim.

Threading the ropes

Fig. : Rope lay-out



35

Thread the ropes through the idlers of the spreader or the headblock. The idlers are on the headblock, if the machine has one. If there is no headblock on the machine, the idlers are on the spreader. Thread the ropes as shown in the figure.

Installing the rope-ends to the drum

A

The rope installation method varies depending on whether the ropes come to the drum straight from the headblock or through the rope idlers. 1 Fasten all the four rope-ends to the drum with one small fas‐ tener (B). 2 Check the balance. 3 Rotate the drum three rounds and then fasten the ropes per‐ manently with larger fasteners (A).

B

A. B.

large fastener small fastener Installing the rope-ends that come straight to the drum

A

Ropes that come straight to the drum are fastened with the fasten‐ ers in the middle of the drum. 1 Lower the service lift chain through the trolley at the point (A). 2 Use a rope lock and a lifting sling to fasten the chain on the ground to the hoist rope. Leave 1.5 metres of the rope-end free. 3 Lift the rope up to the drum. 4 Fasten the end of the rope to the drum with a small fastener.

NOTE Do not tighten the first small single-rope-fastener too much. Avoid bending of bolt. 5

Repeat steps 1-4 to the other rope that comes straight to the drum.

Fig. : Lowering point (A) Installing the rope-ends that come through the idler to the drum Ropes that come through the idlers to the drum are fastened with the fasteners at the end of the drum. Before lifting the rope to the idler, fasten an auxiliary rope to the hoist rope in addition to the chain. Use the auxiliary rope to guide Maintenance manual 308 001 EN


36

A

the rope-end first up from the idler groove (this is the only way to make the rope fit through the hole). 1 Lower the service lift chain next to the groove (A) of the other idler. 2 Use a rope lock and a lifting sling to attach the lift chain to the hoist rope. Leave 7 metres of the rope end free so that it rea‐ ches through the idler to the drum. 3 Attach an auxiliary rope that reaches from the trolley to the ground. 4 Lift the hoist rope with the service lift. Stop the rope before it reaches the trolley. 5 Pull the rope-end with the auxiliary rope up through the idler groove. 6 Lift the rope more with the service lift.

A Fig. : Lowering point (A) 7

584 Nm A

Thread the rope through the idler to the drum and use one small fastener to fasten the rope-end to the hoisting drum.

NOTE Do not tighten the first small single-rope-fastener (A) too much. Avoid bending of bolt. 8 9

Detach the service lift chain from the hoist rope. Repeat steps 1-8 to the other rope that comes to the drum through the idler.

Fig. : Correct torque for double-rope-fastener Balancing the spreader When the ropes are fastened with one small fastener, you can check if the spreader swings when lifted. All ropes must carry an equal amount of the load. If rough adjustment is needed (10 cm or more), the adjustment is done by moving the fastening point of the rope forward on the drum. Move the rope-end with the service lift. Fine adjustment is done later with the adjustment screws of the rope length that are attached to the skews. Final fastening of the hoist rope-ends on the drum When the spreader is roughly balanced, the ropes can be fastened more permanently. Use a weight to make sure that the ropes are straight and tight on the drum. 1 2 3

Rotate the hoisting drum three rounds. When rotating the hoisting drum, make sure that the ropes go to the grooves on the drum. Fasten the double-rope-fasteners to the correct torque (Tight‐ ening torque 584 Nm).



37

Procedures after the installation 1 2

Fine-adjust the spreader balance with the adjustment screws on the skews. Lubricate the ropes.

7.2.5

Performing the trim maintenance (option)

General The trim may be used only when it is required for handling the con‐ tainer. The trim can be used for lowering and lifting one side of the spreader through 3 or 5 degrees. Normally, the trim idler should be in the middle position. Unnecessary running of the trim causes needless wear and may result in premature need for maintenance. The faultless operation of the trim requires regular maintenance in accordance with the manual. Neglecting the maintenance instruc‐ tions can lead to, for example, falling of the container.

5°°

5°°

1

Instructions

WARNING If the lift or trim mechanism shows any sign of malfunction during operation - for example, the load does not remain at the set height stop working immediately and contact service personnel. Neglecting the maintenance of the trim will cause falling of the load which can result in injury. Only two people are allowed to be on trim service platform at the same time. The crane functions must not be used during the maintenance.

CAUTION • •

• •

Prior to maintenance, the load must always be lowered. You must insert the trim locking pin (1) in the locating hole before commencing maintenance. This is to prevent the trim from tilting +/-3° or +/-5°. When installing the hoist ropes, make sure that you also secure the trim with a locking pin. Be sure to remove the locking pin when the maintenance is fin‐ ished.

NOTE The electric brake is equipped with a microswitch that prevents the use of the trim if brake maintenance is neglected. If use of the trim is prevented, neglecting proper brake maintenance has caused the brake to wear past the permitted level.



38

Maintenance points • • • • • • • • • •

Observing the operation of the device while working Adjusting the end and middle limits when necessary Checking the gear oil level Changing the gear oil Cleaning the gear breather Checking the electric brake according to the instructions Adjusting the electric brake when necessary Lubricating the idler slide bearing with grease Inspecting the general condition of the structures during main‐ tenance Checking the tightness of the bolts

Changing the oil

2

1

A

4

6

7

3

6 5

7 5

The trim gear oil change has to be made from the service platform installed for this purpose. Remove the grille (1) and go down the ladder (2) to the service platform (3). 1

2 3 4 5

Move the trim with the skew-sideshift to the middle of the service platform (point A), so that the trim also functions as a wall for the service platform. Lower the spreader to the ground. Lock the trim to the middle position with the locking pin (4). Place an oil receiver under the trim gear. Open the oil drain plugs (5) and let the oil drain into the receiver.



39

NOTE Oil volumes are 17 litres and 2 litres 6 7 8

Open the filling plugs (6). After the oil has drained, close the drain plugs (5). Fill new oil to the level of the level plugs (7) and close the fill‐ ing plugs (6).

7.2.6

Checking the tightness of fixing bolts of the hoist equipment

Instructions

A 8

2

5 1

6

7 4

3 5

A.

You must insert the trim locking pin (A) in the locating hole before you start the maintenance.



40

1. 2. 3.

4.

Clean the screws and nuts and area around them. Check every screw and nut of items from 1 to 8 of the figure shown above. Check visually for any defects. Possible defects are: loose screws or nuts • damage • cracks • deformations • corrosion • Use a tap testing for screws without a nut. Hit screws lightly with a tap test hammer and listen the sound (or use an analysis instrument). If a screw is damaged or the prestress is low, the sound is lower compared to an undamaged, sufficiently tight screw.

Replace a defect screw or nut with a new one with all the character‐ istics of the original. Check tightening torques from Chapter F Tech‐ nical data.


7.2.7

Alignment of the hoist machinery

Instructions

A

NOTE All adjustments related to the hoist machinery coupling are made by moving the electric motor longitudinally, laterally, or vertically.

D

E B

A. B. C. D. E.

C

Motor mounting bolt (4 pcs) Lateral motor adjustment screw (4 pcs) Motor adjustment screw lock nut (8 pcs) Longitudinal motor adjustment screw (4 pcs) Shim



H F

41

1

Adjust the correct distance (250 ±0.25 mm) between the sleeves with the motor adjustment screws (D) by measuring the distance between the measurement points (H) using, for example, a tape measure and micrometer.

2

Adjust the alignment of the sleeves using a square tool (max. 0.5 mm).

G

60

60

250 ±0,25mm

0.5mm

F= Axle of the hoist gear G= Axle of the electric motor H= Measuring point from center line

3

Perform lateral adjustment with the motor adjust‐ ment screws (B). b) Perform vertical adjustment by placing shims (E) under the motor, at the mounting bolts. Check the alignment of the sleeves with a dial gauge . •

a)

•

a) b)

Rotate the transmission shaft via the brake plate to view the measurement result on the dial gauge. If necessary, use the motor adjustment screws (B) and shims (E) to adjust.



0.1°

0.1°

42

max. 0,4mm

Ø120

4

Check the alignment (max. 0.4 mm) of the sleeves with the dial gauge. Rotate the transmission shaft via the brake plate to view the measurement result on the dial gauge. b) If necessary, use the motor adjustment screws to adjust (D). After all adjustments are performed, tighten the motor mount‐ ing bolts (A) (tightening torque: 629 Nm). Lock the motor adjustment screw lock nuts (C) with Loctite 641 thread-locking compound. •

5

A

6

D

a)

E B

C

7

I

J

Install the shaft tube (I) and the transmission-side lamella (J) between the sleeves.

NOTE The direction of installation of the mounting bolts (L).



K

43

Install the motor-side lamella (K) between the sleeve and the shaft tube.

NOTE The direction of installation of the mounting bolts (L). 9

Tighten the mounting bolts of the coupling (tightening torque: 280 Nm).

L

L

7.2.8

Load cell calibration using the touch panel (if E-One2)

Instructions Calibrating force sensors

NOTE Use a test container that gives equal load for all ropes (not an unbal‐ anced test container). The weight should be as close as possible to the rated load. 1 2

3 4 5 6 7 8

Press the calibration button in the RTG status display. It opens the calibration screen of the force sensors. Lower the spreader on the test container until the ropes are loose. You may have to use the bypass switch. The sensors zeroed indicator turns to green when the ropes are loose enough. Fill the weight of the test container in the related field in the force censors calibration screen. Close the twistlocks. Hoist up the test container. Wait until the raw signal value is unchangeable in the calibra‐ tion screen of the force sensors Press the Calibration button. Check the weight with empty spreader. The left and right val‐ ues should be equal (±1.0T).



44

7.2.9

Lubrication points

7.2.9.1

Centralized greasing points of trim (option)

Instructions

B

C

A

A

P A-A A

C

A B

NOTE You must insert the trim

locking pin (P) in the locating hole before

you start the maintenance. This is to prevent the trim +/-3° or +/-5°.

Pos

Components

A

Trim wheel bearing

B

Planetary gear axle front bearing

C

Planetary gear axle back bearing


from tilting

7 Load handling – 7.2 Lifting/lowering 7.2.9.2

Headblock

Instructions

A.

Intermediate sheaves for hoist ropes


45

46

7 Load handling – 7.4 Side movement

7.4

Side movement

7.4.1

Description

General The trolley frame assembly is made of welded steel. The operator cabin is bolted on the trolley and travels with it across the crane span width. The hoist drum is attached at the other end of the trolley frame and two hoist cable pulleys at the opposite sides of trolley frame. The driving speed is adjusted by a trolley joystick located at the operator’s cabin. An inverter adjusts the speed of the motor on the basis of joystick position. When joystick is moved, trolley brake is opened and it will stay open until driving speed goes back to zero, then brake will close. When braking (decelerating), the trolley motor acts as an electrical brake. When the trolley joystick is returned to the neutral position, the trol‐ ley motor starts to brake. During the trolley movement, the PLC system monitors the position by a speed signal. When the trolley is near the end stop, the PLC starts to slow down the trolley according to predefined parameters. When the trolley bypasses the slowdown check point (3), the PLC checks that the speed does not exceed the given limits. In case the software end stop limit (2) is bypassed, the overtravel limit switch (1) send a signal which activates an E-stop. The E-stop stops trolley by closing the trolley brake immediately. There are proximity sensors at the software synchronization points (4) in both driving directions. When the proximity sensor is activated, the PLC synchronizes the trolley position.



47

1.

Overtravel limit switch (hardware)

2.

The overtravel limit stops the trolley movement immediately. The trolley movement is possible only with the bypass function. End stop limit (software)

3.

The end stop limit stops the trolley movement. Slowdown checkpoint (hardware)

4.

The PLC checks the trolley travel speed at the checkpoint. If the speed is too high for controlled slowdown, the PLC exe‐ cutes an emergency stop. Synchronization point (software)

5.

The PLC verifies the trolley position at a synchronization point. Slowdown start point (software) The slowdown start point begins. The location of the slowdown start point varies depending on the travelling speed.

Diesel generator power supply The trolley movement is generated by the AC generator, rectifier, inverters and electric drive motors. The system is powered by the AC generator, which is run by a diesel engine. The regenerative power from the motor is fed via the DC link to the braking units. The braking units feed all excess energy to the brak‐ ing resistors. The braking resistors transfer the braking energy to heat.. Zero emission power supply The trolley movement is generated by the rectifier, inverters and electric drive motors. The system is powered by an external power source through a cable connection. When the power supply voltage is more than 1 kV, the crane is equipped with a medium voltage transformer. The regenerative power from the motor is fed via DC link to the Active Interface Module (AIM). The AIM unit feeds all excess energy to the electricity distribution network.



48

Trolley position, speed curves and limits

12 11 13

1

2

3

4

5

6

hw = hardware limit sw = software limit 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

overtravel limit (hw) end stop limit (sw) slowdown checkpoint (hw) synchronization point (hw) slowdown start (sw) slowdown start (sw) synchronization point (hw) slowdown checkpoint (hw) end stop limit (sw) overtravel limit (hw) max speed speed curve position curve


7

8

9 10


Function description of the trolley travel

600-625 VDC

300-425 VAC

4

The item numbers in parentheses refer to the circuit diagram.


49


50

Pos

Function

Signal description

1

The diesel engine generates the power required by the AC generator.

2

The AC generator (G01) produces electric power to the system.

~300 – 425 VAC, 30 – 60Hz

3

The main circuit breaker (F01) protects the system from overload and shortcircuit currents.

~300 – 425 VAC, 30 – 60Hz

4

The auxiliary inverter converts electric power to the auxiliary loads like air conditioning, lightning, etc.

~400 – 440 VAC, 50 – 60Hz

5

Main fuses (F2) protect the generator inverter from overload.

~300 – 425 VAC, 30 – 60Hz

6

The generator inverter (U5) converts alternating current for the direct current intermediate circuit. (DC link)

~300 – 425 VAC /~600 – 625 VDC

7

The inverter (U3) receives the electric power from the DC link and converts the DC power into adjustable frequency AC power.

600 – 625 VDC / 0 – 400 VAC, 0 – 50 Hz

8

The trolley joystick (S701) sends a setpoint signal to the inverter via Profibus.


9

The brake (Y601) opens when the inverter starts to control the motor and the motor starts to produce torque.

PLC – Brake contactor 24VDC, Brake contactor – brake 400 VAC, 30 – 60Hz

10

The inverter controls the direction of rotation and speed of the trolley motor (M604).

~ 0-400 VAC, 0 – 50 Hz

11

The PLC monitors the temperature of the trolley motor with the temperature sensors


12

The PLC monitors the speed of the motors with the pulse encoder (B602) on the motor.


13

The PLC resets trolley position by a proximity switches (S606, S606).

Proximity switch – PLC : 24VDC


Reference


Pos

Function

Signal description

14

The PLC uses a cam switch to check the trolley overtravel at both ends and the trolley speed at the slowdown area (S605)

Cam switch – PLC : 24VDC

15

When braking, the trolley motor acts as an electrical brake. The trolley motor starts to brake when the trolley joystick goes to the neutral position


16

The regenerative power produced by an inverter is fed via the DC link to the braking units (A1 - A2)

~670 VDC

17

The braking units feed all excess energy to braking resistors. The braking resistors (R91 – R92) transfer the braking energy to heat.

~670 VDC

18

When the motor rotation speed is zero (motor stopped), the brake (Y601) closes.

PLC – Brake contactor 24VDC, Brake contactor – Brake 400 VAC, 50 – 60Hz


51

Reference


52

Function description of the trolley travel (zero emission power supply)

PLC

PLC

14 9, 16

15

1, 18 540 - 600 VDC

7 ~

2

17 3

6

8

~

5

4

400 - 440 VAC

11

M~

°C

3

12 10, 19

PG 13 The item numbers in parentheses refer to the circuit diagram.



Pos

Function

Signal description

1

Electrical power is supplied from an external power source through a cable.


2

Electrical power is led through a cable reel slip ring box (X160).


3

The medium voltage transformer transforms the supply voltage into a lower voltage. The transformer is applicable only when the power supply from the external power source is over 1 kV.


4

The main circuit breaker (F150) protects the system from overload and short-circuit currents.

400 – 440 VAC, 50 – 60Hz

5

The Main supply contactor (K50) connects the external power supply to the RTG electical system.

400 – 440 VAC, 50 – 60Hz

6

The main fuses (F2) protect the rectifier from short-circuit currents.

400 – 440 VAC, 50 – 60Hz

7

The rectifier (U5) converts alternating current into direct current for the direct current intermediate circuit. (DC link)

400 – 440 VAC / 540 – 600 VDC

8

The inverter (U4) receives the electric power from the DC link and converts the DC power into adjustable frequency AC power.

540 – 600 VDC / 400 – 440 VAC, 0 – 51 Hz

9

The trolley joystick (S701) sends a setpoint signal to the inverter via Profibus.


10

The brake (Y601) opens when the inverter starts to control the motor and the motor starts to produce torque.

PLC – Brake contactor: 24 VDC Brake contactor – brake: 400 VAC, 50 – 60Hz

11

The inverter controls the direction of rotation and speed of the trolley motor (M604).

~ 400 VAC, 0 – 51 Hz

12

The PLC uses the temperature sensors to monitor the temperature of the trolley motor.



53

Reference


54

Pos

Function

Signal description

13

The PLC uses pulse encoder (B602) to monitor the speed of the motors.


14

The PLC resets the trolley position by a proximity switch (S606).


15

The PLC uses a cam switch (S605) to check the trolley overtravel at both ends and the trolley speed at the slowdown area.

Cam switch – PLC: 24 VDC

16

When braking, the trolley motor acts as an electrical brake. The trolley motor starts to brake when the trolley joystick goes to the neutral position.


17

The regenerative energy generated during braking is fed via DC link to the Active Interface Module (AIM) (U7).

~680 VDC

18

The AIM unit feeds all excess energy to the electricity distribution network.

19

When the motor rotation speed is zero (motor stopped), the brake (Y601) closes.

PLC – Brake contactor: 24 VDC Brake contactor – Brake: 400 VAC, 50 – 60Hz


Reference


7.4.2

Component position

Trolley drive motor and gear

1 2

1. 2.

Motor Gear Skew motor and gear

1 2 1. 2.

Motor Gear


55


56

Cam limit switch The cam limit switch (S605) is used for monitoring the overtravel limits and slowdown checkpoints. The cam limit switch (1) has two contacts to both trolley travel directions. The contacts give inputs when the cam comes in contact with the limit bar (2).

A 1

B

A)

Overtravel limit

B)

Stops the trolley movement immediately. The trolley movement is possible only with the bypass function. Slowdown checkpoint The PLC checks the trolley travel speed at the checkpoint. If the speed is too high for a controlled slowdown, the PLC exe‐ cutes an emergency stop.

2

A B

B

A

Synchronization proximity switches The proximity switches (S606, S607) are installed to the trolley. The sensing plates (1) are located on the left crossbeam.

3



57

Trolley skew proximity switches

1 2 3

S608 (1)

Left side

Forward

S609 (2)

Left side

Backward

S632 (3)

Left side

Stop

S610 (1)

Right side

Forward

S611 (2)

Right side

Backward

S633 (3)

Right side

Stop



58

7.4.3

Adjustment of the trolley chains

Instructions

C

1

2

3

4

Tol e r a n c e ± 1c m

II

TR O LLE Y

I

II

TR O LLE Y

I

A

B 5

II

TR O LLE Y

I

C

IMPORTANT Adjust the chain so that the measurement between the bumpers and the end plates are equal at both sides.


7 Load handling – 7.4 Side movement 1 2 3

4 5 6 7

8

Drive the trolley to the gate end (1). Lock the trolley with the locking device (2). Measure the distance between the trolley bumpers and end stop plates. Make sure that the measurement is equal on both sides. The tolerance for the margin is ±1 cm. Open the trolley brake (3) manually. Rotate the propeller shaft (4) by hand, until the chains are tight (BI). Hold the tension with the brake disk by closing the brake (3). Tighten the nut (5) until the chain is tight (CII). Tighten the left chain from the walking platform and the right chain from the service hatch. Open the locking device (2).

7.4.4

Installation of the skew pulling device

Instructions

2,3 2,3

E

59

1

Left end

1

2,3

Section A--A Left end 2,3

Right end


1

60

7 Load handling – 7.4 Side movement Place the flange bearings (1) at the left end so that the dimension (E) is as small as possible. After that the screws and nuts (2, 3) are tightened thoroughly about 200 Nm. Place the bearings in the right end so that required geometrical tol‐ erances are obtained.

NOTE Remove the sprocket assembly of the skew device during mainte‐ nance, for example when changing the bearing unit. If the sprocket assembly is not removed for maintenance, the bearing units installation bolts cannot be tightened to the required torque.

7.4.5

Removing the skew motor

Preparations Prepare the tools: sleeve (M24, M7), wrench and screw driver. Safety • • • •

Put wood block under the skew motor for protection. Do not lay the skew motor directly to the ground without wood blocks. Obey the safety instructions all the time. Wear safety helmet, safety shoes when work on site. Prepare a clean and safe work area. Make sure that you keep the disassembled parts in good con‐ dition to prevent rusting.

Removing the skew motor (under hoist drum) 1. Clean the skew motor.

2. Removing the wiring 1) Remove the cover with sleeve M7 or M8.



2) Remove the cover with sleeve M7 or M8.

3) Remove the cable M608


61

62


4) Remove the cable Y608.

3. Remove the cover

4. Unscrew the bolt.



1

Short retaining screw (standard components)

2

Lock washer

3

Washer

4

Circlip

6

Customer shaft

63

5. Unscrew the 4 bolts of the support one by one.

Fig. : Installation with standard components

6. Remove the motor.

WARNING The falling down motor can cause personal injury and material dam‐ age. Make sure that you take the motor safely.



64

7.4.6

Jacking and wheel change of trolley

Instructions

3 4 2 284 mm

1020 ton

154 mm

1

6

5 1 2 3 4 5

Remove the falling prevention clamps (1). Jack up the wheel below the trolley box-frame. Use the jack (5). The lifting capacity is 10 - 20 ton. When the wheel is lifted off the rail (4), place a support between the rail and the trolley box-frame. Remove the end plate and the buffer (2). Remove the axle of the wheel (3).

NOTE The axle weight is 40 kg (88 lbs). 6

Roll off the wheel along the rail (6).

NOTE The wheel weight is 148 kg (326 lbs).

IMPORTANT Make sure that there is no danger in the service environment that could possibleendanger the personnel.



7.4.7

65

Checking the tightness of fixing bolts of the trolley

Instructions

2

1

3 4 4 5 1. 2. 3.

4.

6

Clean the screws and nuts and area around them. Check every screw and nut of items 1...6 of the figure shown above. Check visually for any defects. Possible defects are: loose screws or nuts • damage • cracks • deformations • corrosion • Use a tap testing for screws without a nut. Hit screws lightly with a tap test hammer and listen the sound (or use an analysis instrument). If a screw is damaged or the prestress is low, the sound is lower compared to an undamaged, sufficiently tight screw.





66

7.4.8

Changing the lubrication oil of the hoist, trolley and skew gears

General With every oil change, check the breathers for impurities and clean if necessary. Hoist gear

2

1

5 1. 2. 3. 4. 5. 6. 7.

3

6

4

When changing oil to the hoist gear, after the oil has been drained remove the magnetic plug (7) and clean and replace it.

7

Breather Sight glass Fill hole Breather Temperature gauge Drain hole Magnetic plug



67

Trolley gear

2 4

1

3

Pos

Trolley gear

1

Drain hole

2

Fill hole

3

Sight glass

4

Breather

Skew gear

DANGER Immediate risk of crushing. Always use the emergency switch on the trolley when servicing the skew gear. The emergency switch prevents the skew gear from operating during the service.



68

Changing the oil

CAUTION Avoid skin contact with oil. Use protective gloves. Be careful not to discharge oil into the environment. Use an appropri‐ ate container and deliver the oil to a hazardous waste collection point. Take care to ensure absolute cleanliness. Impurities in oil cause damage to the gear. 1 2 3 4 5 6

3

Place a suitable container below the draining plug (1). Remove the draining plug (1). Drain the oil into a container. Close the draining plug (1) when the oil is flown out. Remove the oil filling plug (3). Add new oil through the oil filling plug (3). The maximum oil level is the lower edge of the oil level sight glass. The minimum oil level is 4 mm below the oil level sight glass. For the oil type, see Chapter F Technical data.

1 1. 2. 3.

2

Activating the vent plug

Draining plug Oil level sight glass Autovent plug / Oil filling plug

Remove the spring pin from the vent plug.

7.4.9

Lubrication points

7.4.9.1

Component position

Central lubrication system Some of the lubrication points of the trolley are centralized by pipes to a location easier to access.



1

69

9 7,8

2,3

10

6

5

4 11

Pos

Qty

1

Trolley wheel

1

2

Sprockets for the trolley moving

6

3

Trolley wheel

1

4

Cardan shaft

1

5

Trolley gear bearing

2

6

Cardan shaft

1

7

Sprockets for the trolley

6

8

Trolley wheel

1

9

Trolley wheel

1

10

Transfer chain bearing for the skew

2

11

Axle for the sheave

4



70

Manual lubrication points

1

4 2 3 2

4 3

5



Pos 1

71

Qty Intermediate sheaves for the hoist ropes

2

Hoist gear bearings and seal

2

NOTE

2

Grease through the grease nipple only when the shaft is rotating.

3

Hoist drum bearings

2

4

Antisway drum (option)

2

5

Axle for the trolley gear

1

Bearings for the trolley motor (volume 40 g)

NOTE 6

Use specified grease for motor bearings. For more information, see chapter F Technical data in this manual and the information plate of the motor.

2

Bearings for the hoist motor (volume 40 g)

NOTE 7

Use specified grease for motor bearings. For more information, see chapter F Technical data in this manual and the information plate of the motor.

2

Manual lubrication points of the skew machineries

DANGER Immediate risk of crushing. Always use the emergency switch on the trolley when servicing the skew gear. The emergency switch prevents the skew gear from operating during the service.



72

1

(2)

(2) (2)

1

1

(2)

1

Pos

Qty Skewing traveller, four wheels

1

NOTE

4

Keep grease out of the bearing travel surfaces (3).

(2)

Transfer chain bearing, free from lubrication (can be greased if necessary)


4

7 Load handling – 7.9 Load carrying Bromma

7.9

73

Load carrying Bromma

Safety

DANGER The spreader is equipped with automatic functions which may cause a risk of injury. Observe the following functions when servicing or repairing the spreader: 1. 2.

3.

The twistlocks turn automatically to the closed position when all the feelers are in the upper position. The spreader extends and retracts automatically when the length selection button is pressed in the cab. Do not put your hands in the maintenance holes during the startup or when the machine is running. The hoist ropes move during the automatic functions. No per‐ sonnel are allowed in the operating range of the rope system and the hoist ropes during the operation of the machine.

DANGER Make sure that the engine and the main power are off before starting the maintenance. There is a risk of crushing on the spreader frame during the mainte‐ nance. Be extremely cautious when performing any maintenance inside the spreader frame. The service personnel must be familiar with the risks related to spreader function and movements. In case of emergency, use the emergency switch on the trolley to stop the machine. Make sure that the person on the ground level stays a safe distance from the spreader during maintenance.

Storage of the spreader When detached from the crane, store the spreader on a mainte‐ nance rack or on a container and keep it’s twistlocks locked. For long term storage instructions contact Cargotec.



74

Changing the spreader to the RTG with headblock

CAUTION Always use an appropriate spreader with the RTG. Always replace the broken spreader immediately.

NOTE The spreader can be operated from any of the following three posi‐ tions. Operator’s cabin EE-House Remote control

1. 2. 3.

Only one control position can be active at a time and the control stand selection from the main operator’s panel has to be selected to allow remote control or control from the EE-house. 1 2 3 4 5 6

7

Lower the spreader on the container or a maintenance rack. Secure the spreader in place by locking the twist locks. Shut down the crane and cut off the main switch of the machine to cut off power from the spreader. Open the headblock twistlocks. Disconnect spreader cables, pipes and other connection from the headblock. Position the headblock on the new spreader, reconnect cables, close headblock twistlocks and open the spreader twistlocks to detach it from the maintenance rack. Power up the machine and test the spreader’s functions.

7.9.1

Inspection of headblock (if using) twistlocks

Description

NOTE The twist-locks must be checked: FIRST TIME after 5000 operating hours or 2 years whichever occurs first. After that they must be checked once a year.

1

2

3 1. 2. 3. 4.

Locking device Turning lever Nut for catch Twist-lock

4



75

Disassembly and assembly 1. 2. 3. 4. 5. 6.

Lower top-lift on the ground or over container. Open locking device (1) of twist-lock’s turning lever by remov‐ ing screw from vertical pipe, and then removing locking piston. Turn the lever (2) 90°. Headblock is then separated from top-lift spreader. Remove wedge from the top of twist-lock by untightening both M8 screws. Unscrew nut for catch (3). Turning lever can then be lifted off, and twist-lock is released.

NOTE Check the condition of twist-locks as explained in spreader twistlock inspection instructions Assembly of twist-lock is done in a reversed manner.

7.9.2

Spreader stabilizer

7.9.2.1

General

Description Kalmar stabilizer system improves productivity of RTGs in difficult wind conditions by damping swinging motion of a spreader. Stabilizer has practically no effect on the spreader movements in other directions than rotation. That is why the stabilizer is a compli‐ mentary system for other electric spreader movement damping sys‐ tems. When operator activates the stabilizer, the controller calculates the best counter-motion against the rotating spreader and sends side shift motor control commands to PLC. Based on controller com‐ mands PLC operates the electric motor contactors and trolley move‐ ment attenuates the spreader rotation.

Fig. : Spreader swinging motion.


76


Fig. : Simplified block diagram of the spreader stabilizer system Troubleshooting Stabilizer fault tracing table is shown in Table 1. It is good practice to check communication between the stabilizer module A901 and CAN/ Profibus gateway A650 using diagnostic LEDs, before replac‐ ing any hardware or doing more complicated troubleshooting.



77

Table:Stabilizer fault tracing. FAULT

POSSIBLE CAUSE

CORRECTIVE ACTION

Stabilizer signal light is always off

No power in A901 or B650

If LEDs are check fuse

Broken lamp

Check the lamp and change if necessary

Error in CAN-bus

Refer to attached electrical drawings

Sensor error

Sensor error If CAN bus OK and A901 has healthy heart beat, change sensor B901

Error in CAN-bus

Refer to attached electrical drawings

Sensor error

Sensor error If CAN bus OK and A901 has healthy heart beat, change sensor B901

Wrong parameters in PLC

Check the stabilizer parameters on Operator’s panel

Broken side shift motor contactor

Check contactors

Sensor error

If CAN bus OK and A901 has healthy heart beat, change sensor B901

Stabilizer signal light is always on

Stabilizer signal light is blinking 30 seconds but rotation is not damping

off,

motor

A650 diagnose using LEDs In normal operation the LEDs are never switched off, i.e. they either flash or shine permanently. The flash sequences, which are listed in the following table are repeated about every six seconds.


78

7 Load handling – 7.9 Load carrying Bromma Table:CAN and Profibus diagnostics using LEDs in A650. Led#

Function

Status

Meaning

Corrective action

LED1 (red)

CAN bus status

off

no power supply

Check 24 V power supply

1 x short flash

CAN error

Check CAN bus wiring.

3 x short flash

CAN off

Check CAN bus wiring.

shortlonglong

CAN warning

-

on

CAN OK

off

no power supply

Check 24 V power supply

1 x short flash

looking for bit rate

Check the PROFIBUS connection. Fault in wiring in PROFIBUS cable, short circuit, terminating impedance in wrong position.

2 x short flash

bit rate is monitored

Check the PROFIBUS address specified

3 x short flash

waiting for parameter telegram

Parameter telegram is faulty. Diagnose via SIMATICManager or system function SFC13 (DPNRM_D G)

Fig. : Position of diagnostic LEDs.

LED (red)

2

module PROFIBU S status


bus

-


Led#

LED (red)

Function

3

PROFIBU S data exchange

79

Status

Meaning

Corrective action

4 x short flash

waiting for configuratio n telegram

Configuratio n telegram is faulty. Diagnose via SIMATICMa nager or system function SFC13 (DPNRM_D G)

on

PROFIBUS OK

-

off

no data exchange

-

on

data exchange via PROFIBUS

-

A901 module on a spreader A901 microcontroller module controls the operation of the stabilizer ( Figure). The essential part of smooth operation of the system is the communication with PLC of a crane. A simple diagnostic system has been implemented into the stabil‐ izer software to help fault tracing. There is a heart beat LED in a module, which indicates if an error has been detected or status is normal.

Fig. : A901 module Normal operation LED is flashing slowly at 2 seconds interval.



80

Operation when error has been detected LED is flashing fast. Three errors has been configured: 1. 2. 3.

CAN bus error no PLC error and no parameters error.

You can conclude a source of the error by counting how many times LED is blinking in one sequence.Table 3 shows the number of blinks for each error type. Table:Errors indicated by heart beat LED of MCC module. Number of blinks

Error

Description

CAN bus error

There is something wrong with the communication of the CAN bus

no PLC detected

No messages are received from PLC

no parameters from PLC received

PLC has not sent parameters

1

2

7

7.9.3

Spreader cable

Instructions

CAUTION If the rotation direction of the cable in the cable cage is clockwise, the cable will be damaged. The cable (A) must be installed to the cable cage (B) so that the rotation direction is anticlockwise.

NOTE B

Check the cable for damage and lubricate the cable with grease (e.g. Microlube GL 261 or similar) for better sliding of the cable. Also check that the cable mounting and the connections are tightened properly.

A

Fig. : View from top into cable basket



7.9.4

81

Changing the spreader cable

Dismantling the spreader cable

NOTE Before dismantling the spreader cable, stop the crane and the control module.

WARNING Wear a safety harness and exercise caution when you work in high places. 1. Fix the cable support with a belt to prevent it from falling down.

2. Lift up the spreader to the limit position and then lift down the spreader.

3. Remove the connector and pipe brackets.


82


4. Remove the cable support and the net.

5. Take the cable out of the collector.

6. Clear up the area and prepare for re-installation.

NOTE After dismantling, you can reuse the net if it is in good condition



83

Installation of the spreader cable

Tools: forklift, fork wrench, mobile crane, sling, stainless steel tie, cable net, heat shrink tube, heat gun, cable clamp. 1

Lift up the cable coil, or put the cable coil up by releasing cable bracket.

NOTE Put the spreader cable on wood plate or canvas. Do not lay the spreader cable down directly to the ground without wood plate or can‐ vas.



84

method 1 method 2 (recommended)

2 3

Release the cable wring by rolling the cable coil when take the spreader cable down from the cable coil. Press the rear end of the cable net to make it open，and then insert the spreader cable into the cable net.

NOTE Press the rope device section by section, let the spreader cable enter into the cablenet section by section, so that the net is in close contact with the cable.


7 Load handling – 7.9 Load carrying Bromma 4

85

Bind the cable net end with a stainless steel tie（5×300） (A).

B A

5

Fix the cable net rope end to the bracket (B).

B

C

B

D

6

7

E

Pull the bracket to make sure the cable net stretches com‐ pletely (C). (The cable net may move a little distance when you pull the bracket). Fasten the cable clamp (D).

B C

D

E 8

Keep the cable above the net (E) loose. The cable must not carry the cable weight directly.

E


86


After tightening the cable gland, waterproof the cable gland with a heat shrink (250 mm).

NOTE Apply glue to the inside of the heat shrink.

10

Lift up the spreader cable by a jib hoist or mobile crane, and then release the cable twists.



87

11

After lifting up the cable, put the cable end into the cable bas‐ ket.

12

Connect the cable end that outside the cable basket to the cable plug, or hard-wire the cable end outside the cable bas‐ ket into the terminal block of the junction box.

NOTE During installation there is no need to fix both sides of the cable.


88


13 14

Let the cable counter-clockwise into the basket. Fix the cable with a pipe clamp (F).

F



89

15

After putting all cables into the cable basket, remove the sling from the cable.

16

Lift the spreader up to the trolley bottom and fix the spreader cable bracket according to the drawing (refer to the spreader manual). Make sure that the upper cable can not slide freely and the cable plug or the cable in the terminals block does not carry the cable weight directly.

WARNING Wear a safety harness and exercise caution when you work in high places.


90


Adjust the aerial cable repeatedly and lubricate, and then fix the bracket completely.

NOTE Release the un-necessary torsion within the cable, otherwise the cable can be twisted and over-tightened and finally be damaged.

NOTE Lubricate the cable according to the specifications in the drawing. Make sure area around the cable is clean.

7.9.5

Load sensing system (option)

Description There is a logic display for maintenance personnel located on spreader. Display has the following information: • • •

Fig. : Bromma SCS3-PLC display for maintenance personnel.

total load under the spreader load under the spreader eccentricity of the load

7.9.6

Lift hook (option)

Description The lift hook is a special hoisting appliance used for non-container loads. The hook is mounted on a hook frame. The hook frame is directly connected to the headblock (instead of the spreader). The crane must be run in hook mode to use the lift hook. With only the headblock attached, the pretension in the ropes is small. For this reason these safety limitations are automatically in effect: Maintenance manual 308 001 EN


• • • •

91

The hoisting and veering speed are limited The hoisting height is limited The accelerations are limited The tension in the spreader cable (if present) is limited

Installing the lift hook 1 2

Put the crane to service position before any maintenance work. Place the spreader on the ground and keep on spreading until slack rope appears at the sheaves of the headblock.

WARNING The crane operator coordinates the activities of at least 2 persons.

CAUTION The hoist ropes can fall next to the hoisting sheave. 3 4 5 6

Turn off the spreader and the crane. Disconnect the plug from the spreader and plug it in the dummy socket on the headblock. Unlock the 4 twistlocks of the headblock. Hoist the headblock, but not higher than necessary.

DANGER Clamping danger. Do not hoist the headblock higher than necessary.

CAUTION When hoisting with empty headblock the ropes will sag too much. To prevent this, the hoisting equipment should be installed between the legs. When installing the hoisting equipment, move the trolley as little as possible. 7

Place the headblock above the hook frame by moving the trol‐ ley and the crane.

WARNING Do the crane movements with reduced speed.

CAUTION With empty headblock the speeds and hoisting height are limited.


92


Lower the headblock safely on top of the hook frame, and connect the frame to the headblock.

The crane is ready for production.


1

Table of content 9 Frame, body, cab and accessories

3

9.2 Safety and emergency equipment 9.2.1 Emergency stop buttons

3 3

9.2.2 Safety switches

4

9.2.3 Service of the anemometer (option)

5

9.2.4 Collision prevention system

7

9.12 Frame 9.12.1 Checking and tightening the frame joint bolts 9.12.2 Inspecting welded steel structures for fatigue cracks

8 8 9

9.12.3 Checking the tightness of fixing bolts of the power unit

15

9.12.4 Checking the tightness of fixing bolts of stairs and ladders

16

9.12.5 Checking the mounting of the cabin

18


2


9 Frame, body, cab and accessories – 9.2 Safety and emergency equipment

3

9

Frame, body, cab and accessories

9.2

Safety and emergency equipment

9.2.1

Emergency stop buttons

Description

B

G

1

A

F

E C

I

D


H

4


Emergency stop buttons Function

A

B

C

D

E

F

G

H

Stopping all movements

X

X

X

X

X

X

X

X

X

X

Stopping the diesel engine (if equipped) Stopping rotation of the cable reel (Zero Emission RTG)

I

X

Cutting off power supply to the inverters by opening main contactors in the EE-house (Zero Emission RTG)

X

X

Emergency push button is released by turning the button’s knob counterclockwise.

9.2.2

Safety switches

Description

CAUTION Failure in using these safety equipment can result in death or serious injury and/or damage to the crane and other property.



5

A

B Fig. : The locations of the safety switches A. B.

Service crane Spreader The safety switches are used to disconnect the actuators from the main circuit. The safety switch A stops the movements of the service crane. The safety switch B stops the movements of the spreader.

9.2.3

Service of the anemometer (option)

Instructions

CAUTION The anemometer is exposed to impurities such as sand and salt that can get inside the rotating cup. Impurities cause friction that can break the anemometer. 1 2 3 4

Use an allen wrench to loosen the setscrew on the side of the wind cups. Remove the wind cups and clean the exposed portion of the shaft with a damp cloth or cotton swab. Clean the wind cups with water and a mild liquid detergent. Rinse thoroughly before replacing.



6

NOTE Do not use or add grease, oil or a spray lubricant of any kind.

2

A. B.

5

When replacing the wind cups (1), slide them up the shaft (2) as far as possible.

6 7

Tighten the setscrew (3). Make sure that the wind cups spin freely. If they do not, the bearings may be worn and need factory-replacement.

1

Incorrect Correct

3



9.2.4

7

Collision prevention system

Cat-whiskers Cat-whiskers (1) are located in front of side frames. Lubricate cat-whiskers by using aerosol spray.Lubrication interval 2000 hours or at least 4 Months. Turn cat-whiskers left and right a couple of times.

1

1

Gantry collision prevention laser scanners (option)

A

The four gantry collision prevention laser scanners are mounted to frames above the corner wheels. Check the general alignment of the scanner when performing maintenance on the ground level.

CAUTION Do not use aggressive detergents or abrasive cleaning agents to clean the optics cover. Strong chemicals and abrasive materials can cloud up or scratch the plastic. Static charges cause dust particles to be attracted to the optics cover A. Use a clean and soft brush to remove the dust from the optics cover A and wipe it with a damp clean cloth regularly. For example, when performing other maintenance on the ground level.


9 Frame, body, cab and accessories – 9.12 Frame

8

9.12

Frame

9.12.1

Checking and tightening the frame joint bolts

Instructions

A

A

A.

Frame joint bolts

CAUTION The frame joint bolts must always be checked for tightness and con‐ dition when the frame is placed under high stress, for example, when the machine motion has been stopped with an exceptionally abrupt emergency stop when carrying load or after collisions.



1. 2.

3.

9

Clean the screws and nuts and area around them. Check visually for any defects. Possible defects are: loose screws or nuts • damage • cracks • deformations • corrosion • For some of the screws, use a tap testing. Hit screws lightly with a tap test hammer and listen the sound (or use an analysis instrument). If a screw is damaged or the prestress is low, the sound is lower compared to an undamaged, sufficiently tight screw.

Replace a defect screw or nut with a new one with all the character‐ istics of the original. Tightening torque 900 Nm (667 ft-lbf).


9.12.2

Inspecting welded steel structures for fatigue cracks

General All welded steel structures of the crane must be checked yearly for fatigue cracks. Pay special attention to the objects pointed out in the section Most critical welded joints on page 11. Fatigue crack growth The fatigue cracks will become large enough to be detectable by means of nondestructive testing methods, i.e. MT, UT or DPT. Some cracks are detectable by visual inspection before fracture increase. If the fatigue cracks occur, in many cases the remaining elements of the structure will prevent serious damage so long as the crane is immediately taken out of service and repaired. Periodic inspection is required to detect fatigue cracks that have growth to a significant size in order to avoid serious failure in the crane structure. When the crack is found, repair is necessary Restoring the structure to its original condition is recommended. Sometimes this is not practical, and a change in geometry by cutting and grinding means is more economical. 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 overload in the crane during operation. If such cracks are found, a review of the operation must be made to see if overload is occurring, and remedial measures must be developed to avoid future overloading. The cracking may be due to differences in geometry between the actual detail and the tested detail. In this case, it may be economical to modify the geom‐ etry.


10

9 Frame, body, cab and accessories – 9.12 Frame 9.12.2.1

Test procedures

Abbreviations Type of test

Symbol

Magnetic Particle Test

MT

Dye-Penetrant Test

DPT

Visual Test

VT

Ultrasonic Test

UT

Dye-penetrant 1

Clean and dry the test surface thoroughly. Use chemical sol‐ vents, vapour degreasing, or mechanical methods to cleaning.

NOTE The mechanical cleaning, such as grinding, blasting or wire brushing, may change the test results. 2

Use one of the following type penetrants in conjunction with the proper procedure to get satisfactory results • • •

water soluble penetrant post emulsifiable penetrant solvent removable penetrant

Magnetic particle 1 2

Clean the test surface of loose rust scale and moisture. Clean the painted surfaces at all points of welding rod contact.

NOTE Grinding, brushing or blasting do not affect results of testing in most instances. 3

A magnetic field can be applied to the test material with • • •

permanent magnet yoke which is an electromagnet type of device passing high amperage current through the part

Visual 1 2

Clean the dirt and grease from the surface by wiping with a rag. Look for cracked paint and rust showing through the paint.

Ultrasonic 1

Do the test in accordance with approved method.

Frequency of inspection After the guarantee time a periodic inspection is required. The inspection period is one year.



11

If anything unusual is observed by visual inspection the observation should be confirmed with Magnetic Particle test. Ultrasonic test can also be used to complete Magnetic Particle test. Dye-Penetrant test can be used in such places where it is impossible to use MT or UT. Reporting procedure Photocopy the sketch, if available, or make your own sketch or pho‐ tograph, and indicate the following items on the defect: Cargotec needs to receive report results of any structural inspection to enable comparison with other similar structures throughout the world. • • • • • •

Location Size Extent of defect In toe of weld Propagation into base metal Etc.

Cargotec needs to receive report results of any structural inspection to enable comparison with other similar structures throughout the world. Testing and repairing Please contact the Cargotec service personnel for assistance on testing and for required repairing actions.


12


Most critical welded joints

Frame

A

C

B

Inspection objects A) All welds of the main girders from the centre to distance of 3,5 m (11,5 ft) to both directions. Check also trolley rails. B) All welds of the vertical columns to the height of 3 m (10 ft) from the sill beam. Also check the area for any other possible damages. C) All welds of the wheel fork flanges.


9 Frame, body, cab and accessories – 9.12 Frame Trolley frame

A A

Inspection objects All welds pointed out in the figures • All welds at the cabin attachment points •


13

14


Welding

General Electrical characteristics: The current used is DC-reversed polarity. Joint welding procedure Before chipping, grinding and welding, carefully protect the equip‐ ment that are in danger of being damaged by heat and/or splashing, especially the electric components and cables and so on. The ground cable of the welding unit is joined as near as possible to the welding area.

IMPORTANT The following objects are either special material or a special struc‐ ture. Welding of these must be accepted by Cargotec Finland Oy: • • • • • • • • •

Wheel forks and all of their components Gearboxes Trolley wheels Trolley rails Electric motors Diesel motors Generators Brakes and all of their components Twistlocks (spreader and headblock) Defects Any cracks or blow holes that appear on the surface of any bead of welding must be removed by chipping or grinding to a sound clean metal before depositing the next successive bead of welding. The next successive bead of welding must be deposited in accordance with this procedure. The welds must be free from undercutting and reasonably free of overlap, trapped slag and porosity. Treatment of welding groove Where sound back-welding from the opposite side is possible on double- welded butt joints, the weld from the opposite side must not be made until the joint has been backgouged (carbon arc gouging with subsequent grinding to clean up the welding groove) or backchipped to sound clean metal. Cleaning All traces of slag, flux or foreign material must be removed before laying down the successive welding bead.



15

Preheating and temperature control •

Preheat the welding area to 50ºC (122ºF) before any welding. Dry the cracks and areas to weld.

•

Use gas torches to preheat the welding area and must be for full length of the weld joint prior to starting the weld deposit. Preheat at least an area of 25 cm (10") in all directions from the point of weld. Use only dried welding rods. Do not weld in the rain.

• •

Heat treatment Heat treatment after the repair welding is not necessary.

9.12.3

Checking the tightness of fixing bolts of the power unit

Instructions

1

1. 2.

1 3.

Clean the screws and nuts and area around them. Check visually for any defects. Possible defects are: loose screws or nuts • damage • cracks • deformations • corrosion • Use a tap testing for screws without a nut. Hit screws lightly with a tap test hammer and listen the sound (or use an analysis instrument). If a screw is damaged or the prestress is low, the sound is lower compared to an undamaged, sufficiently tight screw.


NOTE 1.

Power unit mounting screws

Never retighten a loose screw or nut.



16

9.12.4


Instructions

A

A

A

A

A

A A A. B.

A

A

Handrails, walkways, stairs, ladder, and grates. Fastening of the crates.


A

B


17

A

A C

B

A A. B. C.

Handrails, walkways, stairs, ladder, and grates. Fastening of the crates. Safety gate locking mechanism, hinges, general structure. 1. 2.

3.

Clean the screws and nuts and area around them. Check visually for any defects. Possible defects are: loose screws or nuts • damage • cracks • deformations • corrosion • Use a tap testing for screws without a nut. Hit screws lightly with a tap test hammer and listen the sound (or use an analysis instrument). If a screw is damaged or the prestress is low, the sound is lower compared to an undamaged, sufficiently tight screw.


18

9 Frame, body, cab and accessories – 9.12 Frame Replace a defect screw or nut with a new one with all the character‐ istics of the original. Check tightening torques from Chapter F Tech‐ nical data.


9.12.5


Instructions 1.

B

2.

A

Do a full cleaning of the inspected areas. Clean the screws and nuts and area around them. Check visually for any defects. Possible defects are: loose screws or nuts • damage • cracks • deformations • corrosion •

Replace a defect screw or nut with a new one with all the character‐ istics of the original.

A. B.

Mounting screws and nuts, cushion. Cabin safety wire.


1. 2.

Check the condition of the cushion. Check the condition of the cabin safety wire. Check for possi‐ ble defects.


1

Table of content 11 Common electrics

3

11.1 Controls and instruments 11.1.1 PC (option)

3 3

11.2 Electric protection 11.2.1 Removing covers of EE-house

6 6

11.5 Distribution of electricity 11.5.1 Energy chain

7 7

11.5.2 Cable reel

10

11.5.3 Brake resistors and transformers

15


2


11 Common electrics – 11.1 Controls and instruments

11

Common electrics

11.1

Controls and instruments

11.1.1

PC (option)

3

General

CAUTION If there is any uncertainty for maintenance tasks the user should contact Control Express Finland. It may be necessary to return the system to the factory default state during maintenance. This may include reinstalling the operating system on a new or formatted hard disk. Control Express Finland will not be held responsible for any loss of pro‐ grams, data or configuration regardless of cause of data loss. Control Express Finland strongly recommends that the customer makes and verifies a backup of any important data before send‐ ing in a computer. Restoring the backups from the customer's backup media is neither a part of the normal maintenance nor covered by the computer’s warranty.

• •

•

Replacing the air filter

IMPORTANT Because the air purity is different on every installation site, it is impossible to give exact instructions on how often the filter should be replaced. Therefore the filter should be taken out every now and then to inspect its condition and replace it when needed. It is strongly recommended that the filter will be changed at least every 4000 h.

A

1

Open the cover of the computer by removing four screws (A) and raising the cover up.


11 Common electrics – 11.1 Controls and instruments

4

B

2 3 4

Remove the four screws (B) of the filter holder and take the fil‐ ter out. Place the new filter and fasten the filter holder with screws. Place the cover and fasten with screws.

Replacing the CPU cooling kit

CAUTION •

•

•

Replacing the CPU cooling kit should be performed using accepted methods and procedures by CEF authorized person‐ nel only. If the cooling kit (heat sink and fan) is not properly installed and the system is turned on permanent damage to the CPU, moth‐ erboard and other electronic components may be incurred. Do not wipe off (accidentally or otherwise) the layer of thermal paste on the bottom of the heat sink.

IMPORTANT It is recommended to change the cooling kit at 16 000 hours of opera‐ tion or every 4 years, whichever comes first. 1 2

Open the cover of the computer by removing four screws (A). Detach the cooling kit fan connector (C) from motherboard.

C


11 Common electrics – 11.1 Controls and instruments 3 4 5

6

5

Remove the cooling kit screws (D) and raise off the cooling kit (heat sink and fan). Remove the film on the bottom of the new heat sink (not ther‐ mal paste). Gently place the heat sink and cooling kit onto the CPU. Make sure that heat sink is properly onto the CPU and screws are fastened properly. Connect the cooling kit fan cable to the fan connector CPU_FAN1 on the motherboard.

D


11 Common electrics – 11.2 Electric protection

6

11.2

Electric protection

11.2.1

Removing covers of EE-house

Instructions

DANGER The electric systems must be serviced and repaired by trained serv‐ ice personnel. Before commencing work, ensure the electric system is de-ener‐ gized. For safety instructions, see Chapter B Safety, section Electric sys‐ tems. 1

Turn the main switch (A) to OFF-position.

2

Remove the screws (12 pcs) to remove the covers of the DC bus bars (B). Remove the screws (10 pcs) to remove the inverter (C) cov‐ ers. After maintenance, attach the covers in reverse order.

A

B

3

B

4

C


11 Common electrics – 11.5 Distribution of electricity

7

11.5

Distribution of electricity

11.5.1

Energy chain

Inspection points Point

Description

Procedure

Fault

1

Check chain wear

Visually inspect chain link surfaces on the inner radius, where the chains slide over each other.

2

Check for obstructions.

Visually inspect E-Chain and troughs for foreign material and mechanical obstructions.

3

Check roller links.

Check the function of rollers on roller chain links.

a) b)

One side worn more than other. Crossbars worn.

b)

a)

b)

Ice, snow, dirt, forgotten tools or other foreign material present.

a)

Corrective action

Roller does not turn freely. Cover plate is gone (inside).

Adjust trough width.

See adjusting of guiding trough. If the crosbars are worn, replace the chain (chain is worn out when this occurs)

Remove before continuing operation. Install guards, shrouds or protective grills as necessary. a)

b)

Replace roller. If necessary, replace chain link. Check the cone. If necessary, replace chain link.

4

Check chain endpoints

Check bolted connections at both ends of chain. Check that the guide plate is tight.

Noises while the chain is running/loose screws.

Tighten all loose screws.

5

Check strain reliefs

Check tightness of strain reliefs at the moving end and the fixed end, also partial strain reliefs, if applicable.

Abrasion of cables, loose cables, missing strain reliefs.

Replace or tighten.

6

Check cables

Extend the upper run to its full length. In this position, the cables must be free and must not be rubbing on the inner crossbars.

a)

b)


Cables are lying tight against the inner crossbars or shelves. Cables lie in waves and not smoothly on the lower crossbars.

a. and b. Loosen the strain relief at the fixed point. Push the cables into the chain until the condition is reached.See

Adjusting length.

the

cable


8

Point

Description

7

Check troughs

Procedure a)

b) c) d)

Fault

Check trough segments for possible damage. Check the vertical trough brackets. Check trough width Check hinge point where applicable.

a) b)

c) d)

Channel segments bent. Screws are loose or missing. Bracket is bent. Width is out of specification. Troughs or pins not aligned. Loose or bent parts.

Corrective action a)

b)

c)

d)

8

Check moving arm

a) b)

c)

Check screw tightness. Manually check moving floating arm side-to-side movement. Clean shaft surface and check for damage or rust.

a) b)

c)

Screws loose or missing. Floating arm does not move. Bearing is blocked. Damage or rust.

a)

b)

c)


Straighten or replace as necessary. Replace or tighten screws according to torque specification. Replace or straighten. Adjust the internal width of the trough. Tighten mounting brackets using a torque wrench. See

adjusting of guiding trough. Adjust troughs and/or reference pins. Replace or tighten as required. See adjusting of guiding trough.

Replace or tighten screws. Use a torque wrench. Attempt to break loose. Replace bearings & shaft as necessary. Grease with Staburags NBU 12K. Repair or replace as necessary. Grease bearing with Staburags NBU 12K.

11 Common electrics – 11.5 Distribution of electricity 11.5.1.1

9

Adjusting of guiding trough

Instructions

Ba a b c

2 +1 mm

2 +1 mm Ba+4 +2

Ba+4=L

L L/2

1

d

Visually inspect chain link surfaces on the inner radius where the chains slide over each other.

NOTE There must be a gap on both sides between the guiding trough and chain.See figure above. Too small gap causes wearing on chain links. Too large gap causes wearing on chain links and crossbars. 2

If one side of the chain (a) is worn more than the other, adjust guiding trough inner width. Use the spacer tool (d) to measure the inner width (Ba). See figure above. B) Loosen the adjusting screws on both sides of the trough (c). C) Move the trough (b) horizontally. D) When the gap on both sides is correct, tighten the adjust‐ ing screws. Replace the chain if the crossbars are worn (chain is worn out when this occurs). Visually inspect chain and troughs for foreign material and mechanical obstructions. Check the function of rollers on roller chain links. A)

3 4 5

A)

If the roller does not turn freely, replace the roller.



10

11.5.1.2

Adjusting the cable length

Instructions Check the cable lengths in the E-chain. They must be adjusted so that the cables run slightly outside the centerline of the E-Chain in the radius. This adjustment can also be made at the moving end, whichever is easier. 1 Detach strain relief clamp (a). 2 Push or pull on the cables (b) to reach the desired effect in the chain (c). 3 Reattach the strain relief clamp.

b a

c

Fig. : Correct cable adjustment

11.5.2

Cable reel

Description The power supply cable is connected to the crane with a cable reel located on top of EE-house. The cable reel rolls the cable in accordance with crane travelling. The cable reel is driven by electric motor equipped with brake. When gantry starts to move, cable reel brake opens and stays open until driving speed goes back to zero then brake will close. When braking (decelerating), cable reel motor is acting as electrical brake, command of braking comes when gantry joystick goes to neutral position. Re-generative power from the motor is fed to DClink where Active Interface Module (AIM) feeds all excess energy to electricity distribution network. The cable reel can be controlled manually from the control stand located nearby the cable reel. To support the cable, the cable is led through a cable guide. Cable slacking or overtensioning is prevented by monitoring the status of the cable guide.


11 Common electrics – 11.5 Distribution of electricity Function description

PLC PLC

20

14

15

9, 16

1, 18 540 - 600 VDC

7 ~

2

17 3

6

8

~

5

4

400 - 440 VAC

11

M~ 3

°C

13 10, 16

12

PG



11


12

Pos

Function

Signal description

1

Electrical power is supplied from external power source through a cable.


2

Electrical power is led through a cable reel slip ring box (X160).


3

Medium voltage transformer transforms the supply voltage into a lower voltage. Transformer is applicable only when the power supply from external power source over 1 kV.


4


400 – 440 VAC, 50 – 60Hz

5

Main supply contactor (K50) connects external power supply to the RTG electical system.

400 – 440 VAC, 50 – 60Hz

6


400 – 440 VAC, 50 – 60Hz

7


400 – 440 VAC / 540 – 600 VDC

8

Inverter (U8) receives the electrical power from the DC-link and converts DC power into adjustable frequency AC power.

540 – 600 VDC / 400 – 440 VAC, 0 – 58 Hz

9

Gantry movement is controlled by joystick.


10

Cable reel brake (Y160) on the cable reel motor opens when inverter starts to control the motor.

PLC – brake contactor: 24 VDC Brake contactor – brake: 400 VAC, 50 – 60 Hz

11

Inverter controls the direction of rotation and speed of the cable reel motor (M160) in accordance with gantry travel.

~ 0-400 VAC, 0 – 58 Hz

12




Reference


Pos

Function

Signal description

13

PLC monitors the temperature of the cable reel motor with temperature sensor (M160).


14

Gantry travel is guided by slowdown system, which controls the speed when closing to end stop limit. Gantry movement is stopped automatically at the end stop limit. These limits are based on amount of cable on the reel. PLC monitors the gantry travel with the geared limit switch (S160) on the cable reel gear.

Cam limit switch – PLC: Profibus

15

PLC monitors the tightness of the cable by proximity switches (S161 S164) on the cable guide.


16

When braking, cable reel motor is acting as electrical brake, command of braking comes when gantry joystick goes to neutral position.


17

Regenerative energy generated during braking is fed via DC-link to Active Interface Module (AIM) (U7).

~670 VDC

18

AIM unit feeds all excess energy to electricity distribution network.

19

When motor is stopped (rotation speed zero), brake (Y160) closes.


20

Cable reel can be monitored and controlled with a control stand on the cable guide.

Control stand – PLC: 24 VDC PLC – inverter: Profibus

13

Reference

Component position Components on the front frame of Zero Emission RTG are shown in the figure below. Component locations vary depending on crane’s equipment.



14

1 3

3

4

5 1. 2. 3. 4. 5.

2

Cable reel Cable guide Main power supply transformer (only when the main power supply voltage is over 1kV) Power unit Auxiliary power unit

5

6, 7

4

1 2

8

3 1. 2. 3. 4. 5. 6. 7. 8.

Proximity switches, cable tension monitoring Geared limit switch Gear Motor Brake Pulse encoder Temperature sensor Slip ring box


11 Common electrics – 11.5 Distribution of electricity 11.5.2.1

15

Changing lubrication oil of the gear

Instructions

2

max 3

min

Pos

Cable reel gear

1

Drain hole

2

Fill hole

3

Sight glass

1 11.5.2.2

Lubrication points

Component position

1

Pos 1

Lubrication points Motor bearings

11.5.3

Brake resistors and transformers

Description Brake resistors convert the braking energy to heat.


Qty 2


16

Component position

A B C D

Brake resistors and transformers are located on the roof of the EEhouse. A) B) C) D)

Transformer Transformer Brake resistors Brake resistor

11.5.3.1

/ Battery box

Checking and cleaning the brake resistor and transformer

Instructions

DANGER The electric systems must be serviced and repaired by trained serv‐ ice personnel. Before commencing work, ensure the electric system is de-ener‐ gized. For safety instructions, see Chapter B Safety, section Electric sys‐ tems.

CAUTION The components may be hot. Wait for the components to cool down before commencing work. The maintenance procedures release dust from the surface of the components. Use personal protective equipment such as gloves, safety goggles, breathing mask and so on. 1 2 3

Isolate the brake resistors and transformers from the power supply. Open the covers of the brake resistors and transformers. Remove the dust and impurities from the surface of the com‐ ponents by using compressed air. For safety instructions, see Chapter B Safety, section Fluid or gas under pressure.


11 Common electrics – 11.5 Distribution of electricity 4 5 6 7 8

17

Check the electrical connections of the brake resistors for oxi‐ dation. Clean the electrical connections of the brake resistors. Check the tightness of the electrical connections of the brake resistors. Check the insulations of the cables visually. Close the covers of the brake resistors and transformers.


18



1

Table of content F Technical data

3

Technical data and dimensional drawing Engine fluid capacities, tightening torques and lubrication points Tightening torques Lubrication points

3 9 10 16

Tightening torques, units of measurement and conversation tables


22

2


F Technical data – Technical data and dimensional drawing

F

Technical data

Technical data and dimensional drawing Technical data Engine Make and model

Cummins QSX 15-C665

Operating principle

Turbocharged, low-emission direct-injection diesel engine with charge air cooler.

Power (ISO 8528)

496 kW@2100 rpm

Number of cylinders

6

Alternator

24 V / 35 A

Starter and PLC batteries

24 VDC / 170 Ah (start) and 24 VDC / 170 Ah (PLC)

Exhaust emissions

Tier 3

Generator Make and model

Stamford HCI 434F1, insulation class H

Running speeds

900-800 rpm, 30-60 Hz

Zero emission power supply Voltage

900 V, 3-phase, 50/60 Hz

Cable reel

Wampfler

Cable length

300 m

Power transmission Operating principle

Electric transmission.

Driven wheels

Two driven wheels in both side-frames. Each driven wheel is equipped with an electric drive motor.

Drive motors, left

Siemens, LE1621-2AB53-4GB4-Z, 30 kW

Hubs, driven

Brevini, PHC3850/SF/68.3/FR B3D

Hubs, nondriven

Brevini, TH510/SF/../..


3

4


Brakes Service brake

Gantry travel braking is done electrically.

Parking brake

Parking brake is operated by spring force, which is released electrically.

Steering Steering system

Turning is performed by an electric motor.

Steering motors

4 x Lönne, 1TZ9 A 112M-6 – 3/3,45kW_H03 +L25+N03+Q02+S03

Steering gears

4 x Brevini, SL4004/9002487/1958/A.D.IEC100-112 V5

Steering brakes

4 x Precima, IP66 with hand release

Tyres Size

21.00-25 40PR RL T/L

Pressure

10 bar (145 psi) drive axle, 10 bar (145 psi) nondrive axle



Hoisting device Hoisting system

Trolley located, electrically operated hoist motor/-gear assembly which rotates the grooved-surface hoist drum.

Hoist motor

Siemens, 1LE1621-3AB53-4GF4-Z, 200 kW

Hoist gear

Kalmar, HG90V4 i=56,957

Hoist clutch

Radex N90

Hoist brake

Bubenzer SB28

Trolley motor

Siemens, 1LE1621-2AB53-4GB4-Z, 30 kW

Trolley gear

Kalmar, TG02V1

Skew gear brake motor

SEW Eurodrive, KA67/T DRS90L8/2BE2

Trim

Kalmar, Trim ±3 degrees with automatic centring

Trim motor

Lönne, 1TZ9 A 132M-4, 11kW

Container lengths handled with the spreader

20’, 40’ . Spreader type: YSX40E Skew movements: ±5° / ±200 mm (±7.9”), switch for automatic centring in the cabin

Hoist rope lengths

Rope 1: 66,620 mm (+/- 50 mm) Rope 2: 65,100 mm (+/- 50 mm) Rope 3: 57,000 mm (+/- 50 mm) Rope 4: 57,000 mm (+/- 50 mm)

Hoist rope diametre

26 mm

Cabin General

Reinforced steelprofile cabin is mounted to trolley via rubber vibration reducers. Cabin travels across the span offering excellent visibility to all working areas.

Control and monitoring system PLC system

PLC ( Programmable Logic Controller ) Logic-controlled electric control and monitoring system.

RMI system

Kalmar RMI ( Remote Machine Interface ) is remote maintenance and monitoring system.

Intercom

Intercom system between rear frame, EE-house and operator’s cabin.


5


6

Weight Machine's total service weight

140,800 kg (310,410 lbs)

Performance Lifting capacity

41,000 kg (90,200 lbs)

Driving speed

Without load: Standard 130 m/min (426 ft/min) With load: Speed and acceleration depend on load under spreader

Lifting speed

Without load: 60 m/min (197 ft/min) With rated load: 30 m/min 98 ft/min)

Lowering speed

Without load: 60 m/min (197 ft/min) With rated load: 30 m/min 98 ft/min)

Trolley travel speed

Without load/with load: Standard 70 m/min (230 ft/min)

Climatic conditions Ambient temperature

-10°C (14°F) .... +45°C (113°F)

Humidity

Max. 99%

Wind speed, operational

0....20 m/s (0....66 ft/s)

Wind speed, performance

operational

limited

20....25 m/s (66....82 ft/s)

Wind speed, wheels in parking position

25....40 m/s (82....131 ft/s)

Wind speed, stowed condition

> 40 m/s (> 131 ft/s)



Dimensional drawing


7

8



F Technical data – Engine fluid capacities, tightening torques and lubrication points

Engine fluid capacities, tightening torques and lubrication points Engine fluid capacities Engine Sisu Fuel tank

1935 l (439 Us gal)

Cooling system

40 l (9 Us gal)

Lubrication

46.5 l (10.6 Us gal)

Maintenance item

Quality

API/ASTM/SAE/ISO/Classification

Fuel tank

High-quality diesel fuel

EN590

Engine cooling system

50% high-quality monoethyleneglycolbased coolant and 50% water. The fluids must be mixed before they are added to the cooling system. Example: Shell GlycoShell

BS6580 (1992) AFNOR (1991) ASTM D 3306

NOTE We use and recommend only glycol-based coolant that does not contain nitrite. This kind of coolant must not be mixed with nitritebased anti-corrosive agent because it may create slag and the cooling effect may be reduced.

Engine lubrication system Ambient temperature: -15 °C - +30 °C

Diesel engine oil SAE 20W-30

E3

-10 °C - +30 °C

Diesel engine oil SAE 30

CG-4

-5 °C - +45 °C


0 °C - +45 °C


-30 °C - +30 °C


-25 °C - +30 °C


-20 °C - +45 °C

Diesel engine oil SAE 15W-40 Example: Shell Rimula Super


9


10

Tightening torques Gantry driveline/axle tightening torques

1 3

6

2

7

3

4

5

5 10 5 9

6

8

5

6

1 2

3

6

3 4

9 6

6 10 4 6



11

Pos

Torque

Screw

Grade

Quantity

1

86 Nm

M12

8.8

4

2

239 Nm

M14

12.9

35

3

1176 Nm

M30

10.9

20

4

200 Nm

M16

8.8

4

5

380 Nm

M20

8.8

48 (8 wheels)

650 Nm

M22

7

67 Nm

M10

10.9

16 (8 wheels)

8

650 Nm

M24

8.8

24 (16 wheels)

9

120 Nm

M16

8.8

2 (16 wheels)

200 Nm

M16

8.8

12 (8 wheels) 8 (16 wheels)

6

10

40 (8 wheels) 48 (16 wheels)

Trolley tightening torques

1

1

2 5

3

2

2 6 9

8

11

10 7

5

8

11

10 2 4


11 9

12


Pos

Torque

Screw

Grade

Quantity

1

655Nm

M24

8.8

12

2

127Nm

M14

10.9

32

3

194Nm

M16

8.8

4

4

379Nm

M20

8.8

4

5

584Nm *)

M24

8.8

24

6

655Nm

M24

8.8

24

7

655Nm

M24

8.8

4

8

655Nm

M24

8.8

6 (1 brake) 12 (2 brakes)

9

1050Nm

10.9

16 (SF15)

2100Nm

M24 M30

10

1290Nm

M30

8.8

8

11

655Nm

M24

8.8

20

16 (SF24)

*) Single rope clamp / Do not tighten too much to avoid the bolt to bend.


F Technical data – Engine fluid capacities, tightening torques and lubrication points Other trolley tightening torques

1 2

4

3


13

14


Pos

Torque

Screw

Grade

Quantity

1

239 Nm

M14

12.9

35

2

200 Nm

M16

8.8

8

3

See the following detail form

4

See the following detail form Torque

Screw

Grade

10 Nm

M6

8.8

23 Nm

M8

8.8

35 Nm

M10

8.8

70 Nm

M12

8.8

Fastening of plastic slide bar 7 Nm


M10

8.8


15

Power unit tightening torques

1

1 3

3

Pos

Torque

Screw

Grade

Quantity

1

379 Nm

M20

8.8

32

3

380 Nm

M20

8.8

16



16

Columns tightening torques

2

Pos

Screw

Grade

Quantity

1

M24

10.9

112

2

M24

10.9

136

NOTE For Geomet coated bolts, tightening torque need to be tested for every bolt pacth. Load on bolt 222 kN for 10.9 and 266 kN for 12.9.

1

1. 2.

lower end of the column upper end of the column

Lubrication points Gantry driveline/axle lubrication

A B

7 2

7 1

7 1 1 7

B

7 1

7 1

A

7 1 B

B

B-B

A

A

A-A

7 9

7 10

7 10

7 3 7 9 7 5 7 7 4

7 4

7 6


7 6 8 7


Pos

Description

Oil type

1

Steering arm

Shell Alvania Grease EP (LF) 1

2

Steering gear unit

Shell Omala S2 G320

3

Wheel hub (8 wheels)

Shell Spirax S6 AXME 75W-90

3 L (8 L Actuall)

4

Wheel angle gear unit (8 wheels)


11.5 L (14.5 L Actual)

5

Wheel hub (16 wheels)


N/A

6

Wheel hub wheels)

(16


N/A

7

Differential wheels)

(16


N/A

8

Angle gear (16 wheels)


N/A

9

Bearings for gantry motor

Esso Unirex N3

40 g

10

Steering linkage

Shell Alvania Grease EP (LF) 1

N/A

driven

carrier

Classification

N/A

ISO VG320EPPAO


Quantity

11.5 L (15.5 L Actual)

17


18

Trolley and hoist equipment lubrication

1

2

3

6

4,5

7

8,9

10

14 12

15

11 16

21

19 18

15 17

13

20



Pos

Description

Oil type

1

Trolley wheel

Shell Alvania Grease EP (LF)1 *

N/A

2

Axles for sheave


N/A

3

Axles for sheaves

intermediate


N/A

4

Sprockets moving

for


N/A

5

Trolley wheel


N/A

6

Axles for trim (option)


N/A

7

Trolley gear unit bearing


N/A

8

Sprockets moving


N/A

9

Trolley wheel


N/A

10

Trolley wheel


N/A

11

Hoist drum bearings


N/A

12

Hoist gear unit bearings


30 g / nipple

13

Bearings for hoist motor

Esso Unirex N3

40 g

14

Hoist gear unit

Shell Omala S2 G 320 (320F)

15

Rollers for skews


N/A

16

Bearings for trolley chain


N/A

17

Skew gear unit


18

Bearings for trolley motor

Esso Unirex N3

19

Trolley gear unit


for

trolley

trolley

Classification

ISO VG320EPPAO

ISO VG320EPPAO

Quantity

183 L (183 L Actual)

1.1 L (1.1 L Actual)

40 g ISO VG320EPPAO


7 L (7.5 L Actual)

19


20

Pos

Description

Oil type

Classification

Quantity

20

Hoist brake

Shell Morlina 10

HL 10 DIN 51524

9.4 L

21

Skew chains

Essolube D3 HP 10W/ Diesel CD 10W

N/A

*NOTE: Temperature dependence on below table

Temperature dependence of recommended grease Oil type

Ambient temperature

Classification

Quantity

Shell Alvania EP1

-10°C.... +45°C

NLGI 1

N/A

Shell Alvania EP0

-15°C.... +10°C

NLGI 0

N/A

Shell Centra W

-30°C.... -5°C

NLGI 00

N/A

Trim (option), emergency brake (option), automatic lubrication sys‐ tem (option)

4

2

3 4 1



21

Pos

Description

Oil type

Classification

Quantity

1

Trim high speed gear unit


ISO VG320EPPAO

2 L (2 L Actual)

2

Trim slow speed gear unit


ISO VG320EPPAO

17 L (17 Actual )

3

Emergency hydraulic unit

Shell TELLUS T46

ISO VG 46

31 L

4

Automatic lubrication system (Option)

brake

Shell Rimula X W10

6 L (6 L Actual)

Cable reel lubrication

1

2

Cable reel lubrication Pos

Description

Oil type

Oil type

1

Bearings for cable reel motor

Esso Unirex N3

N/A

2

Cable reel gear unit

Shell Omala S2 G 100

8 L (2,1 US gal)


Quantity

22

F Technical data – Tightening torques, units of measurement and conversation tables

Tightening torques, units of measurement and conversation tables Tightening torques, recommendations State

Bolt

Nut

Lubrication

1

untreated

untreated

oil

2

bright-galvanized

untreated or bright-galvanized

oil or dry

3

hot-galvanized

untreated

oil or dry



Strength class / Size

8.8

10.9

12.9

State

1

2

3

1

1

M81

27 Nm

24 Nm

30 Nm

39 Nm

46 Nm

M101,25

54 Nm

48 Nm

61 Nm

78 Nm

91 Nm

M121,25

96 Nm

85 Nm

108 Nm

135 Nm

162 Nm

M161.5

230 Nm

205 Nm

260 Nm

323 Nm

388 Nm

M181.5

330 Nm

294 Nm

373 Nm

466 Nm

559 Nm

M4

3.2 Nm

2.9 Nm

3.6 Nm

4.6 Nm

5.5 Nm

M5

6.4 Nm

5.7 Nm

7.2 Nm

9.1 Nm

11 Nm

M6

11 Nm

9.8 Nm

12.5 Nm

16 Nm

19 Nm

M8

26 Nm

24 Nm

30 Nm

38 Nm

45 Nm

M10

52 Nm

47 Nm

59 Nm

74 Nm

89 Nm

M12

91 Nm

81 Nm

103 Nm

128 Nm

154 Nm

M16

220 Nm

198 Nm

250 Nm

313 Nm

375 Nm

M20

430 Nm

386 Nm

490 Nm

620 Nm

732 Nm

M24

750 Nm

668 Nm

848 Nm

1050 Nm

1270 Nm

M30

1480 Nm

1317 Nm

1672 Nm

2080 Nm

2500 Nm

1/4

12.5 Nm

11.1 Nm

14.1 Nm

17.6 Nm

20 Nm

5/16

25 Nm

22.3 Nm

28.3 Nm

35 Nm

42 Nm

3/8

44 Nm

39 Nm

50 Nm

62 Nm

73 Nm

7/16

70 Nm

62 Nm

79 Nm

100 Nm

118 Nm

1/2

107 Nm

95 Nm

121 Nm

151 Nm

178 Nm

9/16

153 Nm

136 Nm

173 Nm

216 Nm

255 Nm

5/8

210 Nm

187 Nm

237 Nm

298 Nm

353 Nm

3/4

370 Nm

390 Nm

418 Nm

524 Nm

619 Nm

Fine M-thread

M-thread

UNC-thread


23

24


Strength class / Size

8.8

10.9

12.9

7/8

594 Nm

528 Nm

671 Nm

839 Nm

990 Nm

1

889 Nm

791 Nm

1005 Nm

1260 Nm

1480 Nm

1 1/8

1260 Nm

1120 Nm

1424 Nm

1780 Nm

2100 Nm

1 1/4

1760 Nm

1565 Nm

1990 Nm

2490 Nm

2940 Nm

1 3/8

2320 Nm

2065 Nm

2620 Nm

3280 Nm

3870 Nm

1 1/2

3060 Nm

2720 Nm

3455 Nm

4320 Nm

5100 Nm

Units of measurement and their abbreviations Unit

Abbreviation

Newton-metre

Nm

Kilopond-metre

kpm

Kilopascal

kPa

Megapascal

MPa

Kilowatt

kW

Kilojoule

kJ

British thermal unit

Btu

Calorie

ca

Inch

in

Foot

ft

Yard

yd

Mile

mile

Centimetre

cm

Metre

m

Kilometre

km



Conversion table, SI units SI unit

Conversion factor

Other than SI

Conversion factor

SI

Nm

x 10.2

= kg·cm

x 0.8664

= lb·in

Nm

x 0.74

= lbf·ft

x 1.36

= Nm

Nm

x 0.102

= kg·m

x 7.22

= lb·ft

kPa

x 4.0

= in.H 2O

x 0.249

= kPa

kPa

x 0.30

= in.Hg

x 3.38

= kPa

kPa

x 0.145

= psi

x 6.89

= kPa

bar

x 14.5

= psi

x 0.069

= bar

kp / cm 2

x 14.22

= psi

x 0.070

= kp/cm 2

N/ mm 2

x 145.04

= psi

x 0.069

= bar

MPa

x 145

= psi

x 0.00689

= MPa

kW

x 1.36

= hp (cv)

x 0.736

= kW

kW

x 1.34

= bhp

x 0.746

= kW

kW

x 0.948

= Btu/s

x 1.055

= kW

W

x 0.74

= ft·lb/s

x 1.36

=W

kJ

x 0.948

= Btu

x 1.055

= kJ

J

x 0.239

= calorie

x 4.19

=J

m/s2

x 3.28

= ft/s 2

x 0.305

= m/s 2

m/ s

x 3.28

= ft/s

x 0.305

= m/s

km/ h

x 0.62

= mph

x 1.61

= km/h

Torque

Pressure (Pa = N/ m 2 )

Power (W = J/s)

Energy (J = Nm)

Speed and acceleration

Horsepower / torque Bhp x 5252 rpm= TQ (lb·ft)

TQ x rpm 5252 = bhp

Temperature


25


26

SI unit

Conversion factor

ºC = (ºF – 32)/1.8

ºF = (ºC x 1.8) + 32

Other than SI

Conversion factor

SI

Flow factor l / min (dm 3 / min)

x 0.264

= US gal / min x 3.785

= l/min

Conversion table, length Unit

cm

m

km

in

ft

yd

mile

cm

1

0.01

0.00001

0.3937

0.03281

0.01094

0.000006

m

100

1

0.001

39.37

3.2808

1.0936

0.00062

km

100000

1000

1

39370.7

3280.8

1093.6

0.62137

in

2.54

0.0254

0.000025

1

0.08333

0.02777

0.000015

ft

30.48

0.3048

0.000304

12

1

0.3333

0.000189

yd

91.44

0.9144

0.000914

36

3

1

0.000568

mile

160930

1609.3

1.6093

63360

5280

1760

1

1 mm = 0.1 cm, 1 mm = 0.001 m

Conversion table, area Unit

cm 2

m2

km2

a

ft2

yd2

in 2

cm2

1

0.0001

-

0.000001

0.001076

0.000012

0.155000

m2

10000

1

0.000001

0.01

10.764

1.1958

1550.000

km2

-

1000000

1

10000

1076400

1195800

-

a

0.01

100

0.0001

1

1076.4

119.58

-

ft2

-

0.092903

-

0.000929

1

0.1111

144.000

yd2

-

0.83613

-

0.008361

9

1

1296.00

in2

6.4516

0.000645

-

-

0.006943

0.000771

1

1 ha = 100 a , 1 mile2 = 259 ha = 2.59 km 2



27

Conversion table, volume Unit

cm3 = cc

m3

l

in3

ft3

yd3

cm3 = ml

1

0.000001

0.001

0.061024

0.000035

0.000001

m3

1000000

1

1000

61024

35.315

1.30796

dm3(l)

1000

0.001

1

61.024

0.035315

0.001308

in3

16.387

0.000016

0.01638

1

0.000578

0.000021

ft3

28316.8

0.028317

28.317

1728

1

0.03704

yd3

764529.8

0.76453

764.53

46656

27

1

1 gal (US) = 3785.41 cm 3 = 231 in3 = 0.83267 gal (UK)

Conversion table, weight Unit

g

kg

t

oz

lb

g

1

0.001

0.000001

0.03527

0.0022

kg

1000

1

0.001

35.273

2.20459

t

1000000

1000

1

35273

2204.59

oz

28.3495

0.02835

0.000028

1

0.0625

lb

453.592

0.45359

0.000454

16

1

1 ton (metric) = 1.1023 ton (US) = 0.9842 ton (UK)

Conversion table, pressure Unit

kp/cm2

bar

Pa=N/m 2

kPa

lbf/in2

lbf/ft2

kp /cm 2

1

0.98067

98066.5

98.0665

14.2233

2048.16

bar

1.01972

1

100000

100

14.5037

2088.6

Pa=N/ m 2

0.00001

0.001

1

0.001

0.00015

0.02086

kPa

0.01020

0.01

1000

1

0.14504

20.886

lbf/in2

0.07032

0.0689

6894.76

6.89476

1

144

lbf/ft2

0.00047

0.00047

47.88028

0.04788

0.00694

1

kg/cm 2 = 735.56 Torr (mmHg) = 0.96784 atm


28



29

Index Adjusting the valve clearances and unit injector rocker arms 1 - 8 Adjustment of the trolley chains 7 - 58 Air intake / exhaust outlet 1 - 14 Air pollution B - 12 Alignment of the hoist machinery 7 - 40 Bleeding the fuel system 1 - 6 Brake resistors and transformers 11 - 15 Brakes 4 - 3 Cable reel 11 - 10 Changing a driven wheel 3 - 10 Changing a non-driven wheel 3 - 16 Changing oil 1 - 26 Changing the coolant and flushing the cooling system 1 - 20 Changing the coolant filter 1 - 19 Changing the lubrication oil 3 - 8 Changing the lubrication oil 3 - 15 Changing the lubrication oil of the hoist, trolley and skew gears 7 - 66 Changing the spreader cable 7 - 81 Checking a cardan shaft 3 - 5 Checking and adjusting the cable reel brake (Zero Emission RTG) 4 - 20 Checking and adjusting the gantry brake 4 - 4 Checking and adjusting the hoist brake 4 - 9 Checking and adjusting the skew brake 4 - 16 Checking and adjusting the steering brake 4 - 6 Checking and adjusting the trim brake (option) 4 - 18 Checking and adjusting the trolley brake 4 - 7 Checking and tightening the frame joint bolts 9 - 8 Checking a rim 6 - 4 Checking the air filter indicator 1 - 15 Checking the coolant level 1 - 19 Checking the generator mounting 2 - 4 Checking the mounting of the cabin 9 - 18 Checking the oil level 1 - 24 Checking the tightness of fixing bolts of stairs and ladders 9 - 16 Checking the tightness of fixing bolts of the hoist equipment 7 - 39 Checking the tightness of fixing bolts of the power unit 9 - 15 Checking the tightness of fixing bolts of the trolley 7 65 Checking the wheel alignment 5 - 6 Checking the wheel hub and the angle gear lubrication oil level 3 - 8 Checking the wheel hub lubrication oil level 3 - 14 Checking tightening torques of the driveline/axle 3 - 3 Check the fan hub bearing clearance 1 - 17 Check the vibration damper 1 - 16 Clean and check the crankcase breather tube 1 - 16

Cleaning the fuel tank 1 - 7 Cleaning wheel hub and rim before installation 6 - 7 Collision prevention system 9 - 7 Common electrics 11 - 3 Complete machine 0 - 3 Component position 3 - 26 Component position 5 - 5 Component position 7 - 12 Component position 7 - 55 Concerning the maintenance and repair personnel B 16 Controls and instruments 11 - 3 Coolant B - 12 Cooling system 1 - 18 Cummins 1 - 3 Daily checks C - 8 Description 7 - 46 Distribution of electricity 11 - 7 Driveline/axle 3 - 3 Driven wheel 3 - 7 Drive shaft 3 - 5 Electrical drive 3 - 19 Electrical transmission 2 - 3 Electric protection 11 - 6 Electric systems B - 4 Emergency stop buttons 9 - 3 Empty dust collector of air filter 1 - 16 Energy chain 11 - 7 Engine fluid capacities, tightening torques and lubrication points F - 9 External cleaning of the radiator 1 - 21 Feedback A - 7 Filling / Changing planetary gear oil 5 - 5 Fire and explosion risks B - 10 Fluid or gas under pressure B - 11 Foreword A - 3 For the service personnel C - 3 Frame 9 - 8 Frame, body, cab and accessories 9 - 3 Fuel system 1 - 3 General safety instructions B - 3 Hoist ropes 7 - 17 Initial checks C - 5 Inspecting welded steel structures for fatigue cracks 9 -9 Inspection of headblock (if using) twistlocks 7 - 74 Installation of the skew pulling device 7 - 59 Instructions for using shore supply (if equipped) B - 17 Jacking and wheel change of trolley 7 - 64 Lift hook (option) 7 - 90 Lifting/lowering 7 - 3 Lifting heavy components B - 8 Load carrying Bromma 7 - 73

30

Load cell calibration using the touch panel (if E-One2) 7 - 43 Load handling 7 - 3 Load sensing system (option) 7 - 90 Lubrication points 3 - 12 Lubrication points 5 - 8 Lubrication points 7 - 44 Lubrication points 7 - 68 Lubrication points F - 16 Lubrication system 1 - 22 Maintenance manual A - 3 Maintenance tables C - 5 Mechanical parts 1 - 8 Noise B - 9 Non-driven wheel 3 - 14 PC (option) 11 - 3 Performing the trim maintenance (option) 7 - 37 Power assisted brake system 5 - 5 Preventive maintenance C - 3 Reading instructions for maintenance table C - 5 Reading this manual A - 5 Refrigerant B - 12 Regulations for safe maintenance work B - 15 Removing covers of EE-house 11 - 6 Removing the skew motor 7 - 60 Removing water from the water separator 1 - 4 Replacing a cardan shaft 3 - 6 Replacing hoist ropes using the mini-hoist 7 - 19 Replacing the air filter 1 - 15 Replacing the fuel filter 1 - 5 Replacing the fuel prefilter 1 - 4 Replacing the hoist ropes using the service lift 7 - 29 Replacing the oil filter 1 - 25 Rotating components and tools B - 14 Safety B - 3 Safety and emergency equipment 9 - 3 Safety instructions B - 4 Safety switches 9 - 4 Scheduled maintenance - Bakes C - 23 Scheduled maintenance - Common electrics C - 54 Scheduled maintenance - Driveline / Axle C - 20 Scheduled maintenance - Engine C - 14 Scheduled maintenance - Frame, body, cab and accessories C - 50 Scheduled maintenance - General C - 11 Scheduled maintenance - Load handling C - 37 Scheduled maintenance - Steering C - 34 Scheduled maintenance - Suspension C - 35 Scheduled maintenance - Technical data C - 60 Service brake system 4 - 3 Service of the anemometer (option) 9 - 5 Service Position B - 4 Several mechanics working on the machine B - 7 Side movement 7 - 46 Solvents B - 9 Spreader cable 7 - 80 Spreader stabilizer 7 - 75

Steering 5 - 3 Suspension 6 - 3 Technical data F - 3 Technical data and dimensional drawing F - 3 Tensioned springs B - 13 Tightening torques F - 10 Tightening torques, units of measurement and conversation tables F - 22 Tightening torques of the wheel nuts 6 - 6 Transmission 2 - 3 Tyre pressure monitoring system (option) 6 - 8 Tyre pressures 6 - 3 Tyres B - 14 Tyres and rims 6 - 3 Vibration B - 9 Working on top of the machine B - 7 Working under the machine B - 8

Cargotec improves the efﬁciency of cargo ﬂows on land and at sea – wherever cargo is on the move. Cargotec’s daughter brands Hiab, Kalmar and MacGregor are recognised leaders in cargo and load handling solutions around the world. Cargotec’s global network is positioned close to customers and offers extensive services that ensure the continuous, reliable and sustainable performance of equipment. Published by Cargotec Corporation. Copyright © Cargotec 2013. All rights reserved. No part of this publication may be reproduced, stored, photocopied, recorded or transmitted without permission of the copyright owner.

Rainbow-Cargotec Industries Co Ltd (RCI) is a joint venture of Cargotec and Jiangsu Rainbow Heavy Industries Co., Ltd. (RHI) in China. RCI supports Cargotec's strategy of a strong local presence in China and other Asian area.

Cargotec Finland Oy Ruskontie 55, P.O. Box 387 33101 Tampere, Finland tel. +358 20 777 5000 fax +358 20 777 5001 www.cargotec.com

Rainbow-Cargotec Industries Co., Ltd. Dangqian Gate, Taicang Port Economic and Technological Development Zone, Suzhou, Jiangsu, China

EMM_41360-41373_GB.pdf

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