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4 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 3 of 8
20 - MAIN HOIST GEARBOX GEARBOX / REDUCER
Description
Location
Observation
Remark
1. Gearbox Gearbox oil - Inspect oil level and oil condition Note : Fill up where applicable
Gearbox #1
Good(
) / Not Good(
)
Gearbox #2
Good(
) / Not Good(
)
Gearbox #1
Good(
) / Not Good(
)
Gearbox #2
Good(
) / Not Good(
)
2. Structure & Frame - Inspect mounting bolts tightness and crack Note : Fill up where applicable 3. Bearing - Inspect abnormal sound Note : Fill up where applicable
4. Temperature (40 ~ 60 degree) Note : Fill up where applicable
5. Housekeeping
Gearbox #1
Good(
) / Not Good(
)
Gearbox #2
Good(
) / Not Good(
)
Gearbox #1 : _________degree
Good(
) / Not Good(
)
Gearbox #2 : _________degree
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
30 - MAIN HOIST DRIVE & BLOWER BLOWER MOTOR
Description
1. Sound inspection Note : Fill up where applicable
2. Check heater Note : For DC motor only
Location
Observation
Remark
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
3. Visual check - Check coupling motor & gear box (Bush Coupling)
Motor #1
Good(
) / Not Good(
)
- Check terminations
Motor #2
Good(
) / Not Good(
)
- Check mounting bolts and frame
Motor #3
Good(
) / Not Good(
)
Motor #4
Good(
) / Not Good(
)
Note : Fill up where applicable
Motor #1
Good(
) / Not Good(
)
- Check rotation
Motor #2
Good(
) / Not Good(
)
- Check running cond
Motor #3
Good(
) / Not Good(
)
- Measure motor demands
Motor #4
Good(
) / Not Good(
)
4. Check blower blower motor cond.
5. Emergency Emergency Motor - Check coupling condition & chain link
Motor #1
Good(
) / Not Good(
)
- Check limit switch working condition
Motor #2
Good(
) / Not Good(
)
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
Motor #3
Good(
) / Not Good(
)
Motor #4
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
6. Air Filter - Check clealiness
7. Housekeeping
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TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 4 of 8
40 - MAIN HOIST WIRE WIRE ROPE INSPECTION
Description
Location
Observation
Remark
1. Visual check - Check broken strands, deformation and kinks
Drum
Good(
) / Not Good(
- Diameter (NOELL/ZPMC-A : 26.2mm~28.0mm )
Backreach
Good(
) / Not Good(
) )
- Diameter (IMPSA : 26.7mm~28.5mm)
Trolley platform
Good(
) / Not Good(
)
- Diameter (MITSUI : 26.2mm~23.3mm) 26.2mm~23.3mm)
Headblock
Good(
) / Not Good(
)
Length #1
Good(
) / Not Good(
)
Length #2
Good(
) / Not Good(
)
Length #3
Good(
) / Not Good(
)
Length #4
Good(
) / Not Good(
)
- Diameter (ZPMC-C : 32.00mm~29.7 6mm) - Broken strands (<18 wires) Note : Fill up where applicable applicable
2. Clips/Clamp and turnbuckles - Check loosed nut and condition
3. Check for lubrication - Check rusty
Length #1
Good(
) / Not Good(
)
Length #2
Good(
) / Not Good(
)
Length #3
Good(
) / Not Good(
)
Length #4
Good(
) / Not Good(
)
All rollers and plates
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
4. Support roller roller and plate - Check condition
5. Housekeeping Housekeeping
50 - MAIN HOIST WIRE ROPE DRUM INSPECTION
Description
Location
Observation
Remark
1. Check wire rope anchor
All drums
Good(
) / Not Good(
)
2. Check bearing bearing any abnormal noise
All drums
Good(
) / Not Good(
)
3. Check groove surface condition
All drums
Good(
) / Not Good(
)
4. Check structure structure and mounting
All drums
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
5. Housekeeping Housekeeping
General Remark :
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TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 5 of 8
60 - MAIN MAIN HOIST SHEAVE AND BEARING INSPECTION
Description
1. Check groove condition condition any damaged or rope trace mark Note : Fill up where applicable
2. Check locking / keeper keeper plate condition Note : Fill up where applicable
3. Check bearing bearing condition Note : Fill up where applicable
4. Housekeeping
Location
Observation
Remark
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Headblock
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Headblock
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Headblock
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
70 - MAIN MAIN HOIST MOTOR AND GEARBOX COUPLING INSPECTION
Description
1. Check abnormal abnormal sound
Location
Observation
Remark
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Check coupling coupling cover Note : Fill up where applicable
3. Check rubber insert insert condition Note : Fill up where applicable
4. Structure - Check bolt tightness and condition
5. Housekeeping
General Remark Remark :
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TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 6 of 8
80 - MAIN HOIST CAM SWITCH INSPECTION
Description
Location
Observation
Remark
1. Cable termination - Check cable damage and breakage at cable lugs
Main hoist drum
Good(
) / Not Good(
)
All switches
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
Main hoist drum
Good(
) / Not Good(
)
Main hoist drum
Good(
) / Not Good(
)
Main hoist drum
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Cam switch functionality - Function test
3. Cam switch coupling tightness - Check bolt tightness Note : Fill up where applicable
4. Check 3-way gear condition Note : Fill up where applicable
5. Driven belt / driven chain / Coupling Driven - Check condition and retigten Note : Fill up where applicable
6. Driven pulley - Check pulley mounting, side guide, wear and crack Note : Fill up where applicable
7. Housekeeping
90 - MAIN HOIST LIMIT SWITCH INSPECTION
Description
Location
Observation
Remark
1. Cable / conduit - Check cable condition, insulation and cable lug
Trolley platform / trolley house
Good(
) / Not Good(
)
Trolley platform / trolley house
Good(
) / Not Good(
)
Trolley platform / trolley house
Good(
) / Not Good(
)
Spreader cable / headblock
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Limit switch - Check positioning, rusty, functionality and mounting
3. Counter weight - Check condition Note : Fill up where applicable
4. Striker - Check condition Note : Fill up where applicable
5. Housekeeping
General Remark :
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TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 7 of 8
100 - MAIN HOIST ENCODER INSPECTION
Description
Location
Observation
Remark
1. Coupling - Check mounting, rusty, alignment and sprider wear
Main hoist motor and drum
Good(
) / Not Good(
)
Main hoist drum
Good(
) / Not Good(
)
Main hoist drum
Good(
) / Not Good(
)
Main hoist drum
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
2. Driven belt / driven chain/ Driven coupling - Check belting condition and any crack Note : Fill up where applicable 3. Driven pulley - Check pulley mounting, side guide, wear and crack Note : Fill up where applicable
4. Electrical - Check cable connection
5. Housekeeping
110 - MAIN HOIST OVER SPEED DETECTOR INSPECTION
Description
Location
Observation
Remark
1. Cable termination - Check cable damage and breakage at cable lugs
Main hoist drum
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
Main hoist drum
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Coupling tightness - Check bolt tightness
3. Check 3-way gear condition Note : Fill up where applicable
4. Housekeeping
120 - SPREADER CABLE REEL INSPECTION
Description
Location
Observation
Remark
1. Spreader drum - Check drum condition
Trolley platform / trolley house
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Trolley platform / trolley house
Good(
) / Not Good(
)
Trolley platform / trolley house
Good(
) / Not Good(
)
- Check cable condition
2. Driven belt / driven chain (cam switch) - Check belting condition and any crack Note : Fill up where applicable
3. Driven pulley (cam switch) - Check pulley mounting, side guide, wear and crack Note : Fill up where applicable
4. Electrical - Check cable connection and slip ring carbon brushes - Check short length cable and junction box
Trolley platform / trolley house
Good(
) / Not Good(
)
Headblock
Good(
) / Not Good(
)
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TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 8 of 8
Description
Location
Observation
Remark
5. Limit switch - Check limit switch condition
Trolley platform / trolley house
Good(
) / Not Good(
)
Headblock
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
6. Absorber - Check condition
7. Housekeeping
130
- SPREADER HEADBLOCK INSPECTION
Description
Location
Observation
Remark
1. Twistlock - Check gap, lock pin and condition
All twistlocks
Good(
) / Not Good(
)
Headblock lock/unlock lever
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Done(
) / Not Done(
)
2. Electrical - Check limit switch and functionality
3. Structure - Check condition, ladder, hand rail and grating
4. Housekeeping
All location
140 - TRIM, LIST AND SKEW (TLS) SYSTEM INSPECTION
Description
Location
Observation
Remark
1. Power pack - Check oil level, condition and cleanliness - Check working pressure (160±10 psi) - Check hose, valve and piping
Backreach / TLS platform / trolley house
Good(
) / Not Good(
)
Pressure : _________ psi
Good(
) / Not Good(
)
Backreach / TLS platform / trolley house
Good(
) / Not Good(
)
All cylinders
Good(
) / Not Good(
)
All motors and pumps
Good(
) / Not Good(
)
All control boxes
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Hydraulic cylinder - Check oil leak, guide roller and condition
3. Positioner sensor - Check wire string, mounting and crack
4. Motor and pump - Check abnormal sound, overheating, and cover - Check electrical connection
5. TLS control panel - Check wire termination, conduit and DC supply - Check door and lock condition
6. Housekeeping
General Remark :
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TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 1 of 8
150 - TROLLEY BRAKE INSPECTION
Description
1. Reserve stroke height (10 mm) - Inspect stroke indicator setting and manual release Note : Fill up where applicable
. ra ng orque
Location
Observation
Remark
Brake #1 (Height : _________ mm)
Good(
) / Not Good(
)
Brake #2 (Height : _________ mm)
Good(
) / Not Good(
)
Brake #3 (Height : _________ mm)
Good(
) / Not Good(
)
Brake #4 (Height : _________ mm)
Good(
) / Not Good(
)
Brake #1 (Torque : ________________ Nm)
Good(
) / Not Good(
)
- Inspect setting and mechanical component
Brake #2 (Torque : ________________ Nm)
Good(
) / Not Good(
)
Note : IMPSA-A : ≥ 977Nm, NOELL /MITSUI/ZPMC-A : ≥ 1890Nm
Brake #3 (Torque : ________________ Nm)
Good(
) / Not Good(
)
IMPSA-B : ≥ 977Nm , ZPMC-B : ≥ 5175 Nm, ZPMC-C : 5500Nm
Brake #4 (Torque : ________________ Nm)
Good(
) / Not Good(
)
All brakes
Good(
) / Not Good(
)
Brake #1 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #1 LHS : ______mm
Good(
) / Not Good(
)
ZPMC-C: Disk wear >20% from 30mm, Pad >3mm
Brake #2 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
ZPMC(Pad : ≥ 3 mm, Disc : ≤ 1.0mm wear on each side)
Brake #2 LHS : ______mm
Good(
) / Not Good(
)
Brake #3 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #3 LHS : ______mm
Good(
) / Not Good(
)
Brake #4 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #4 LHS : ______mm
Good(
) / Not Good(
)
Brake #1
Good(
) / Not Good(
)
Brake #2
Good(
) / Not Good(
)
Brake #3
Good(
) / Not Good(
)
Brake #4
Good(
) / Not Good(
)
Brake #1
Good(
) / Not Good(
)
Brake #2
Good(
) / Not Good(
)
Brake #3
Good(
) / Not Good(
)
Brake #4
Good(
) / Not Good(
)
All servolifters
Good(
) / Not Good(
)
Good(
) / Not Good(
)
3. Air gap - Check any rubbing
4. Brake pad and disc - Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm)
- Check and clean disc surface Note : Fill up where applicable
5. Check AWC condition - Check one way bearing and adjusting nut condition Note : Fill up where applicable
6. Check wedge and shackle kit Note : Fill up where applicable
7. Servolifter / Thruster - Inspect oil, electrical and mechanical part
8. Structure - Check pivot pin, linkage and mounting
9. Limit Switch - Check setting and functionality Note : Fill up where applicable
10. Housekeeping
General Remark :
a. Brake manual release
Good(
) / Not Good(
)
b. Brake release
Good(
) / Not Good(
)
c. Brake pad wear
Good(
) / Not Good(
)
Done(
) / Not Done(
)
All location
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TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 2 of 8
160
- TROLLEY GEARBOX INSPECTION
Description
1. Gearbox oil
Location
Observation
Remark
Gearbox #1
Good(
) / Not Good(
)
- Inspect oil level and oil condition
Gearbox #2
Good(
) / Not Good(
)
Note : Fill up where applicable
Gearbox #3
Good(
) / Not Good(
)
Gearbox #4
Good(
) / Not Good(
)
2. Structure - Inspect mounting bolts tightness and crack Note : Fill up where applicable
3. Bearing - Inspect abnormal sound Note : Fill up where applicable
4. Temperature (40 ~ 60 degree) Note : Fill up where applicable
5. Housekeeping
Gearbox #1
Good(
) / Not Good(
)
Gearbox #2
Good(
) / Not Good(
)
Gearbox #3
Good(
) / Not Good(
)
Gearbox #4
Good(
) / Not Good(
)
Gearbox #1
Good(
) / Not Good(
)
Gearbox #2
Good(
) / Not Good(
)
Gearbox #3
Good(
) / Not Good(
)
Gearbox #4
Good(
) / Not Good(
)
Gearbox #1 : _________degree
Good(
) / Not Good(
)
Gearbox #2 : _________degree
Good(
) / Not Good(
)
Gearbox #3 : _________degree
Good(
) / Not Good(
)
Gearbox #4 : _________degree
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
170 - TROLLEY MOTOR INSPECTION
Description
Location
Observation
Remark
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
Motor #3
Good(
) / Not Good(
)
Motor #4
Good(
) / Not Good(
)
Note : For DC motor only
Motor #1
Good(
) / Not Good(
)
Note : Fill up where applicable
Motor #2
Good(
) / Not Good(
)
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
Motor #3
Good(
) / Not Good(
)
Motor #4
Good(
) / Not Good(
)
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
1. Sound inspection Note : Fill up where applicable
2. Check heater condition
3. Visual check - Check armature winding for burn marks, scratches and damages (For DC motor only) - Check structure and wire termination Note : Fill up where applicable
4. Check motor in running condition for sparks Note : For DC motor only
5. Emergency motor - Check coupling condition
Motor #1
Good(
) / Not Good(
)
- Check limit switch working condition
Motor #2
Good(
) / Not Good(
)
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TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 3 of 8
Description
6. Carbon brush and holder - Check length and condition Note : For DC motor only
Location
Remark
Motor #1 - Top (3 pcs)
Good(
) / Not Good(
)
Motor #1 - Bottom (3 pcs)
Good(
) / Not Good(
)
Motor #1 - Right (3 pcs)
Good(
) / Not Good(
)
Motor #1 - Left (3 pcs)
Good(
) / Not Good(
)
Motor #2 - Top (3 pcs)
Good(
) / Not Good(
)
Motor #2 - Bottom (3 pcs)
Good(
) / Not Good(
)
Motor #2 - Right (3 pcs)
Good(
) / Not Good(
)
Motor #2 - Left (3 pcs)
Good(
) / Not Good(
)
All location
7. Housekeeping
Observation
Done(
) / Not Done(
)
180 - TROLLEY WIRE ROPE INSPECTION
Description
Location
Observation
Remark
1. Visual check - Check broken strands, deformation and kinks
Drum
Good(
) / Not Good(
- Diameter (2 6.2mm~mm)
Backreach
Good(
) / Not Good(
)
- Broken strands (<18 wires)
Trolley platform
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Length #1
Good(
) / Not Good(
)
Length #2
Good(
) / Not Good(
)
Note : Fill up where applicable
2. Clips and turnbuckles - Check loosed nut and condition
3. Check for lubrication - Check rusty
)
Length #1
Good(
) / Not Good(
)
Length #2
Good(
) / Not Good(
)
All rollers and plates
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
4. Support roller and plate - Check condition
5. Housekeeping
190 - TROLLEY WIRE ROPE DRUM INSPECTION
Description
Location
Observation
Remark
1. Check wire rope anchor
All drums
Good(
) / Not Good(
)
2. Check bearing any abnormal noise
All drums
Good(
) / Not Good(
)
3. Check groove surface condition
All drums
Good(
) / Not Good(
)
4. Check structure and mounting
All drums
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
5. Housekeeping
General Remark :
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13 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 4 of 8
200 - TROLLEY SHEAVE AND BEARING INSPECTION
Description
1. Check groove condition any damaged or rope trace mark Note : Fill up where applicable
2. Check locking / keeper plate condition Note : Fill up where applicable
3. Check bearing condition Note : Fill up where applicable
4. Housekeeping
Location
Observation
Remark
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
210 - TROLLEY MOTOR AND GEARBOX COUPLING INSPECTION
Description
1. Check abnormal sound
Location
Observation
Remark
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
2. Check coupling cover Note : Fill up where applicable
3. Check rubber insert condition Note : Fill up where applicable
4. Structure - Check bolt tightness and condition
220
- TROLLEY WHEEL INSPECTION
Description
1. Wheel - Check wheel bearing condition and abnormal sound
2. Structure - Check wheel flange cracks or damages and condition
3. Guide roller - Check bearing and guide roller condition
Location
Observation
Remark
Wheel #1
Good(
) / Not Good(
)
Wheel #2
Good(
) / Not Good(
)
Wheel #3
Good(
) / Not Good(
)
Wheel #4
Good(
) / Not Good(
)
Wheel #1
Good(
) / Not Good(
)
Wheel #2
Good(
) / Not Good(
)
Wheel #3
Good(
) / Not Good(
)
Wheel #4
Good(
) / Not Good(
)
Wheel #1
Good(
) / Not Good(
)
Wheel #2
Good(
) / Not Good(
)
Wheel #3
Good(
) / Not Good(
)
Wheel #4
Good(
) / Not Good(
)
Document No.
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14 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST TROLLEY : Page 5 of 8
Description
4. Floating shaft - Check coupling condition and bolt tighness Note : Fill up where applicable
5. Plumber block - Chek abnormal sound Note : Fill up where applicable
6. Housekeeping
230
Location
Observation
Remark
Floating shaft LHSS
Good(
) / Not Good(
)
Floating shaft LHLS
Good(
) / Not Good(
)
Floating shaft RHLS
Good(
) / Not Good(
)
Floating shaft RHSS
Good(
) / Not Good(
)
Plumber block LHSS
Good(
) / Not Good(
)
Plumber block LHLS
Good(
) / Not Good(
)
Plumber block RHLS
Good(
) / Not Good(
)
Plumber block RHSS
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- TROLLEY RAIL INSPECTION
Description
Location
Observation
Remark
1. Trolley rail structure
- Check greasy or oily
All
Good(
) / Not Good(
- Check rail clip, bolt and nut
All
Good(
) / Not Good(
)
- Check welded part cracked or chipped
All
Good(
) / Not Good(
)
- Check side plate bolt tightness
Boom joint
Good(
) / Not Good(
)
- Check trolley rail gap
Boom joint
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Housekeeping
)
SUPPORTING DOCUMENT
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15 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 6 of 8
240 - TROLLEY LIMIT SWITCH INSPECTION
Description
Location
Observation
Remark
1. Cable and conduit Good(
) / Not Good(
)
All limit switches
Good(
) / Not Good(
)
All flag sensors
Good(
) / Not Good(
)
- Check insulation, termination and condition
2. Limit switch - Check condtion, mounting and functionality
3. Flag sensor - Check condtion, mounting and functionality
4. Slowdown magnet - Check condtion, mounting and functionality
5. Housekeeping
250
Boom tip
Good(
) / Not Good(
)
Backreach
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- TROLLEY ENCODER INSPECTION
Description
Location
Observation
Remark
1. Coupling - Check mounting, rusty, alignment and sprider wear
Trolley motor
Good(
) / Not Good(
)
Trolley motor
Good(
) / Not Good(
)
Trolley LS LHS
Good(
) / Not Good(
)
Trolley motor
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
2. Electrical - Check cable connection
3. Structure - Check mounting, wheel and bearing condition Note : Fill up where applicable 4. Encoder sensor - Check sensor surface and condition
3. Housekeeping
260
- TROLLEY CATENARY INSPECTION
Description
Location
Observation
Remark
1. Wheel bearings - Check abnormal noise
All location
Good(
) / Not Good(
)
2. Trolley wheel - Check any crack or damage on wheel flange
All wheels
Good(
) / Not Good(
)
- Check wheel bracket bolts tighten
All wheel brackets
Good(
) / Not Good(
)
- Check wheel cover bolt tightness
All bolts
Good(
) / Not Good(
)
Note : Fill up where applicable 3. Sheave and bearing - Check groove condition
1. Boom tip LHS and RHS
Good(
) / Not Good(
)
- Check sheave bearing abnormal sound and condition
2. Catenary LS LHS and RHS
Good(
) / Not Good(
)
- Check locking /keeper plate bolts and nuts condition
3. Catenary SS LHS and RHS
Good(
) / Not Good(
)
4. Backreach LHS and RHS
Good(
) / Not Good(
)
Note : Fill up where applicable
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16 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 7 of 8
Description
Location
Observation
Remark
4. Catenary wire rope - Visual check for wear, deformation and kinks Note : Fill up where applicable
1. Drive rope LHS and RHS
Good(
) / Not Good(
)
2. Tie rope LHS and RHS
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
5. Clip and turnbuckle - Check clips and turnbuckles condition Note : Fill up where applicable
6. Structure - Check catenary structure condition Note : Fill up where applicable
1. Catenary LHS
Good(
) / Not Good(
)
2. Catenary RHS
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
7. Guide roller - Check guide roller tighness and condition
8. Support roller - Check support roller, bearing and shaft condition
9. Housekeeping
270 - TROLLEY WIRE ROPE TENSIONER INSPECTION
Description
Location
Observation
Remark
1. Cylinder - Check abnormal sound and cylinder condition - Check hose and any leakage
All cylinders
Good(
) / Not Good(
)
Note : Fill up where applicable
2. Cross joint - Check vibration and any abnormal sound
All location
Good(
) / Not Good(
)
- Check bearing and shaft condition
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All limit switches
Good(
) / Not Good(
)
All limit switches
Good(
) / Not Good(
)
All power units
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
3. Sheave - Check bolt tighness, sheave and bearing condition
4. Limit switch - Check limit switch condition and functionality
5. Hydraulic power pack - Check tank, hose and fitting condition - Check any leakage and oil level
6. Power unit for motor pump - Check abnormal sound, termination and condition
7. Housekeeping
General Remark :
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17 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 8 of 8
280 - FESTOON SYSTEM INSPECTION
Description
Location
Observation
Remark
1. Festoon rail - Check deformation, dents and leveling condition
Along rails
Good(
) / Not Good(
)
All cables
Good(
) / Not Good(
)
All shackles and elastic cords
Good(
) / Not Good(
)
All bumpers
Good(
) / Not Good(
)
All rollers
Good(
) / Not Good(
)
Motor #1 and #2
Good(
) / Not Good(
)
Motor #1 and #2
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
All carrier
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Festoon cable - Check cable and cable clamp mouting condition
3. Sling shackle and elastic cord - Check any cut, broken and wear condition - Check sling shackle missing and condition
4. Festoon bumper - Check mounting and bumber condition
5. Side roller, runner wheel and anti-lift roller - Check roller condition and abnormal sound - Check mounting condition
6. Belting system - Check belting, pulley and bearing condition Note : Fill up where applicable
7. Motor (Brand : VAHLE or WAMPFLER) - Check abnormal sound and mounting condition - Check bolt tightness and motor cover condition Note : Fill up where applicable
8. Trolley festoon box - Check cable termination and slot connection condition - Check door seal condition
9. Festoon carrier - Check carrier condition
10. Housekeeping
General Remark :
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18 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 1 of 4
290
- GANTRY BRAKE INSPECTION
Description
Location
Observation
Remark
1. Gantry brake - Check wire termination - Check friction disc, stationary disc and coil assembly
All brakes
Good(
) / Not Good(
)
- Check mounting cover and silicon seal condition Note : Fill up where applicable
2. Reserve stroke height (10 mm) - Inspect stroke indicator setting and manual release Note : Fill up where applicable
Lanside Height : #1 : ______ mm
#5 : ______ mm)
Good(
) / Not Good(
)
Height : #2 : ______ mm
#6 : ______ mm)
Good(
) / Not Good(
)
Height : #3 : ______ mm
#7 : ______ mm)
Good(
) / Not Good(
)
Height : #4 : ______ mm
#8 : ______ mm)
Good(
) / Not Good(
)
Height : #1 : ______ mm
#5 : ______ mm)
Good(
) / Not Good(
)
Height : #2 : ______ mm
#6 : ______ mm)
Good(
) / Not Good(
)
Height : #3 : ______ mm
#7 : ______ mm)
Good(
) / Not Good(
)
Height : #4 : ______ mm
#8 : ______ mm)
Good(
) / Not Good(
)
Seaside
. ra ng orque
Lanside
- Inspect setting and mechanical component
Torque : #1 : ______ Nm
#5 : ______ Nm)
Good(
) / Not Good(
)
Note : Fill up where applicable
Torque : #2 : ______ Nm
#6 : ______ Nm)
Good(
) / Not Good(
)
Torque : #3 : ______ Nm
#7 : ______ Nm)
Good(
) / Not Good(
)
Torque : #4 : ______ Nm
#8 : ______ Nm)
Good(
) / Not Good(
)
Torque : #1 : ______ Nm
#5 : ______ Nm)
Good(
) / Not Good(
)
Torque : #2 : ______ Nm
#6 : ______ Nm)
Good(
) / Not Good(
)
Torque : #3 : ______ Nm
#7 : ______ Nm)
Good(
) / Not Good(
)
Torque : #4 : ______ Nm
#8 : ______ Nm)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
IMPSA-B : > 207Nm, ZPMC-B : >320Nm, ZPMC-C : 350Nm
Seaside
4. Air gap - Check any rubbing
All brakes
Note : Fill up where applicable
5. Brake pad and disc (Landside) - Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm)
- Check and clean disc surface
Brake #1 RHS : _____mm, LHS _____mm Disc : _____mm
Note : Fill up where applicable Brake #2 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #3 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #4 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #5 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #6 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #7 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #8 RHS : _____mm, LHS _____mm Disc : _____mm
SUPPORTING DOCUMENT
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#REF!
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19 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 2 of 4
Description
Location
Observation
Remark
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
All brakes
Good(
) / Not Good(
)
All servolifters
Good(
) / Not Good(
)
- Check pivot pin, linkage, mounting and cover
All brakes
Good(
) / Not Good(
)
- Check limit switch setting and functionality
All brakes
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
6. Brake pad and disc (Seaside) - Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm)
Brake #1 RHS : _____mm, LHS _____mm Disc : _____mm
- Check and clean disc surface Note : Fill up where applicable
Brake #2 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #3 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #4 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #5 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #6 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #7 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #8 RHS : _____mm, LHS _____mm Disc : _____mm 7. Check AWC condition - Check one way bearing and adjusting nut condition Note : Fill up where applicable
8. Servolifter / Thruster - Inspect oil, electrical and mechanical part Note : Fill up where applicable
9. Structure and limit switch
10. Housekeeping
300 - GANTRY GEARBOX INSPECTION
Description
Location
Observation
Remark
1. Gearbox oil - Inspect oil level and oil condition
All gearboxes
Good(
) / Not Good(
)
All gearboxes
Good(
) / Not Good(
)
All gearboxes
Good(
) / Not Good(
)
All gearboxes
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Structure - Inspect mounting bolts tightness and crack Note : Fill up where applicable 3. Bearing - Inspect abnormal sound Note : Fill up where applicable
4. Temperature (40 ~ 60 degree) Note : Fill up where applicable
5. Coupling - Check rubber insert for coupling condition - Check circlips condition Note : Fill up where applicable
6. Housekeeping
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20 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 3 of 4
310
- GANTRY MOTOR INSPECTION
Description
Location
Observation
Remark
1. Sound inspection - Check any abnormal sound
All motors
Good(
) / Not Good(
)
All motors
Good(
) / Not Good(
)
All motors
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Electrical - Check wire termination at motor termination box
3. Structure - Check cover, mounting and body codition
4. Housekeeping
320 - GANTRY RAIL CLAMP AND ANCHOR PIN INSPECTION
Description
Location
Observation
Remark
1. Rail clamp hydraulic unit - Check oil condition and level - Check piping, any leakage and hose condition
All units
Good(
) / Not Good(
)
All motors
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check wire termination
2. Rail clamp motor - Check any abnormal sound and vibration - Check wire termination
3. Limit switch - Check condition and functionality - Check leakage and mounting condition
4. Structure - Check any leakage and cylinder condition - Check brake shoe / lining condition - Check mounting condition Note : Fill up where applicable
5. Housekeeping
330 - GANTRY ANTI-COLLISION CRANE TO SHIP INSPECTION
Description
Location
Observation
Remark
1. Anti-collision limit switch - Check functionality
Right and left side of boom girder
Good(
) / Not Good(
)
Right and left side of boom girder
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check wire termination and micro switch condition
2. Wire rope - Check wire rope rusty and stringness Note : Fill up where applicable
3. Housekeeping
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21 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 4 of 4
340 - GANTRY ALARM SYSTEM INSPECTION
Description
Location
Observation
Remark
1. Siren - Check siren functionality and condition
All sirens
Good(
) / Not Good(
)
All warning lights
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check wire termination condition
2. Warning light - Check bulb and motor condition - Check lamp cover and mounting condition - Check wire termination condition
3. Housekeeping
350
- GANTRY WHEEL INSPECTION
Description
Location
Observation
Remark
1. Wheel - Check wheel bearing condition and abnormal sound
All wheels
Good(
) / Not Good(
)
All wheels
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Structure - Check wheel flange cracks or damages and condition - Check mounting condition
3. Housekeeping
General Remark :
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22 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 1 of 5
360
- BOOM BRAKE INSPECTION
360.1 - SERVICE BRAKE
Description
1. Reserve stroke height (10 mm)
Location
Observation
Remark
Brake #1 (Height : _________ mm)
Good(
) / Not Good(
)
Brake #1 (Torque : ________________ Nm)
Good(
) / Not Good(
)
Service brake
Good(
) / Not Good(
)
- Inspect stroke indicator setting and manual release . ra ng orque - Inspect setting and mechanical component Note : IMPSA-A : ≥ 1890Nm, NOELL/MITSUI/ZPMC-A: ≥ 14850 Nm, IMPSA-B : >7200Nm, ZPMC-B : >5940Nm, ZPMC-C: >6000Nm
3. Air gap - Check any rubbing
Brake pad RHS : ________mm
Good(
) / Not Good(
)
- Check and clean disc surface
Brake pad LHS : ________mm
Good(
) / Not Good(
)
- Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm)
Brake disc
Good(
) / Not Good(
)
Service brake
Good(
) / Not Good(
)
Service brake
Good(
) / Not Good(
)
Service brake
Good(
) / Not Good(
)
Good(
) / Not Good(
)
4. Brake pad and disc
: ________mm
ZPMC (Pad : >3.0 mm, Disc : >1.0mm wear on each side )
5. Check AWC condition - Check one way bearing and adjusting nut condition
6. Check wedge and shackle kit
7. Servolifter / Thruster - Inspect oil, electrical and mechanical part
8. Structure - Check pivot pin, linkage and mounting
9. Limit Switch - Check setting and functionality
a. Brake manual release
Good(
) / Not Good(
)
b. Brake release
Good(
) / Not Good(
)
c. Brake pad wear
Good(
) / Not Good(
)
360.2 - EMERGENCY BRAKE
Description
Location
Observation
Remark
1. Hydraulic power pack - Check oil condition and working pressure (150-180 bar)
Hydraulic oil tank
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
2. Hydraulic cylinder and block - Check leakage
3. Proximity Sensor & Motor - Check setting and functionality
All location
- Check electrical and mechanical parts
Brake #1 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
- Inspect pad and disc (Pad : ≥ 8 mm, Disc : ≥ 28 mm)
Brake #1 LHS : ______mm
Good(
) / Not Good(
)
- Check and clean disc surface
Brake #2 RHS : ______mm
Good(
) / Not Good(
)
Brake #2 LHS : ______mm
Good(
) / Not Good(
)
Brake #3 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #3 LHS : ______mm
Good(
) / Not Good(
)
Brake #4 RHS : ______mm
Good(
) / Not Good(
)
Brake #4 LHS : ______mm
Good(
) / Not Good(
)
Done(
) / Not Done(
)
4. Brake pad and disc
Note : Fill up where applicable
5. Housekeeping
All location
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23 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 2 of 5
370 - BOOM GEARBOX / REDUCER
Description
Location
Observation
Remark
1. Gearbox oil - Inspect oil level and oil condition
Gearbox #1
Good(
) / Not Good(
)
Gearbox #1
Good(
) / Not Good(
)
Gearbox #1
Good(
) / Not Good(
)
Gearbox #1 : _________degree
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Structure - Inspect mounting bolts tightness and crack
3. Bearing - Inspect abnormal sound
4. Temperature (40 ~ 60 degree)
5. Housekeeping
380 - BOOM MOTOR
Description
1. Sound inspection
Location
Observation
Remark
Boom motor
Good(
) / Not Good(
)
Boom motor
Good(
) / Not Good(
)
Boom emergency motor
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Visual check - Check structure and wire termination
3. Emergency Motor - Check coupling condition - Check limit switch working condition
4. Housekeeping
390 - BOOM WIRE ROPE INSPECTION
Description
Location
Observation
Remark
1. Visual check Wire rope drum
Good(
) / Not Good(
- Broken strands (<18 wires)
Boom tip
Good(
) / Not Good(
)
- Diameter : IMPSA-A : >28.8mm, IMPSA-B : >34.2mm,
A-Frame
Good(
) / Not Good(
)
- Check loosed nut and condition
Length #1
Good(
) / Not Good(
)
Note : Fill up where applicable
Length #2
Good(
) / Not Good(
)
Wire rope
Good(
) / Not Good(
)
All plates
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check broken strands, deformation and kinks
)
ZPMC-A/C : 36mm~33.4mm, ZPMC-B : 32.4mm NOELL/MITSUI : 30mm~2 7.9mm
2. Clips and turnbuckles
3. Check for lubrication - Check rusty
4. Support plate - Check condition
5. Housekeeping
SUPPORTING DOCUMENT
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24 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 3 of 5
400 - BOOM WIRE ROPE DRUM INSPECTION
Description
Location
Observation
Remark
1. Check wire rope anchor
All drums
Good(
) / Not Good(
)
2. Check bearing any abnormal noise
All drums
Good(
) / Not Good(
)
3. Check groove surface condition
All drums
Good(
) / Not Good(
)
4. Check structure and mounting
All drums
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
5. Housekeeping
410 - BOOM SHEAVE AND BEARING INSPECTION
Description
1. Check groove condition any damaged or rope trace mark
2. Check locking / keeper plate condition
3. Check bearing condition
4. Structure and mounting - Check condition and bolt tightness
5. Housekeeping
Location
Observation
Remark
Boom tip
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
420 - BOOM MOTOR AND GEARBOX COUPLING INSPECTION
Description
1. Check abnormal sound
Location
Observation
Remark
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Check coupling cover Note : Fill up where applicable
3. Check rubber insert condition Note : Fill up where applicable
4. Structure and mounting - Check bolt tightness and condition
5. Housekeeping
General Remark :
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Effective Date
#REF!
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25 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST BOOM : Page 4 of 5
430 - BOOM LIMIT SWITCH INSPECTION
Description
Location
Observation
Remark
1. Cable / conduit - Check cable condition, insulation and cable lug
A-Frame
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Limit switch - Check positioning, rusty, functionality and mounting
3. Striker - Check condition
4. Housekeeping
440 - BOOM CAM SWITCH INSPECTION
Description
Location
Observation
Remark
1. Cable termination - Check cable damage and breakage at cable lugs
Boom drum
Good(
) / Not Good(
)
All switches
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
Boom drum
Good(
) / Not Good(
)
Boom drum
Good(
) / Not Good(
)
Boom drum
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Cam switch functionality - Function test
3. Cam switch coupling tightness - Check bolt tightness
4. Check 3-way gear condition Note : Fill up where applicable
5. Driven belt / driven chain - Check belting condition and any crack Note : Fill up where applicable
6. Driven pulley - Check pulley mounting, side guide, wear and crack Note : Fill up where applicable
7. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
#REF!
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Effective Date
#REF!
Page
26 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 5 of 5
450
- BOOM LATCH INSPECTION
Description
Location
Observation
Remark
1. Servolifter - Check oil condition and any leakage - Check linkage split-pin and conduit condition
A-Frame
Good(
) / Not Good(
)
All limit switches
Good(
) / Not Good(
)
Boom latch
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check rubber bumper Note : Fill up where applicable
2. Limit Switch - Check condition and functionality Note : Fill up where applicable
3. Structure and mounting - Check condition and bolt tightness Note : Fill up where applicable
4. Power pack - Check oil condition and any leakage Note : Fill up where applicable
5. Plunger - Check plunger and spring condition Note : Fill up where applicable
6. Housekeeping
General Remark :
SUPPORTING DOCUMENT
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Effective Date
#REF!
Page
27 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 1 of 3
460 - EMERGENCY STOP SYSTEM INSPECTION
Description
1. Machinery house - Check functionality and condition Note : Fill up where applicable
2. Trolley
Location
Observation
Remark
Electrical room (inside)
Good(
) / Not Good(
)
PLC panel
Good(
) / Not Good(
)
DC bus shift cub
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
Trolley / hoist emergency station
Good(
) / Not Good(
)
- Check functionality and condition
Trolley house inside
Good(
) / Not Good(
)
Note : Fill up where applicable
Trolley house panel
Good(
) / Not Good(
)
Boom emergency station
Good(
) / Not Good(
)
- Check functionality and condition
Boom top outside
Good(
) / Not Good(
)
Note : Fill up where applicable
Boom top inside
Good(
) / Not Good(
)
Boom girder end
Good(
) / Not Good(
)
3. Boom
4. Cabin - Check functionality and condition Note : Fill up where applicable
5. Portal - Check functionality and condition Note : Fill up where applicable
6. Others - Check functionality and condition Note : Fill up where applicable
Checker cabin panel
Good(
) / Not Good(
)
Cabin operator console
Good(
) / Not Good(
)
Boom opeartor cabin
Good(
) / Not Good(
)
Portal landside left
Good(
) / Not Good(
)
Portal landside right
Good(
) / Not Good(
)
Portal seaside left
Good(
) / Not Good(
)
Portal seaside right
Good(
) / Not Good(
)
Gantry operation station
Good(
) / Not Good(
)
High voltage cable reel station
Good(
) / Not Good(
)
TLS station
Good(
) / Not Good(
)
Done(
) / Not Done(
)
All location
7. Housekeeping
470 - FLOODLIGHT INSPECTION
Description
Location
Observation
Remark
Boom tip
Good(
) / Not Good(
)
- Check functionality and condition
Boom joint
Good(
) / Not Good(
)
- Check wire termination
Boom center cross beam
Good(
) / Not Good(
)
Boom center
Good(
) / Not Good(
)
1. Boom floodlight
2. Trolley floodlight - Check functionality and condition
Trolley platform
Good(
) / Not Good(
)
Operator cabin
Good(
) / Not Good(
)
- Check wire termination Note : Fill up where applicable
3. Machinery house
Seaside
Good(
) / Not Good(
)
- Check functionality and condition
Right hand side
Good(
) / Not Good(
)
- Check wire termination
Left hand side
Good(
) / Not Good(
)
Landside RHS
Good(
) / Not Good(
)
Landside LHS
Good(
) / Not Good(
)
Note : Fill up where applicable
SUPPORTING DOCUMENT
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#REF!
Effective Date
#REF!
Page
28 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 2 of 3
Description
Location
Observation
Remark
4. Backreach - Check functionality and condition - Check wire termination
Backreach
Good(
) / Not Good(
)
Multi-functional platform
Good(
) / Not Good(
)
Note : Fill up where applicable
5. Portal beam - Check functionality and condition
Right hand side
Good(
) / Not Good(
)
- Check wire termination
Left hand side
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
6. Housekeeping
480
- OPERATOR CABIN INSPECTION
Description
Location
Observation
Remark
1. Master controller / joystick - Check functionality and condition
Right side consol
Good(
) / Not Good(
)
- Check wire termination
Left side consol
Good(
) / Not Good(
)
Wall fan
Good(
) / Not Good(
)
- Check functionality and condition
Cabin lamp
Good(
) / Not Good(
)
- Check wire termination
Power socket
Good(
) / Not Good(
)
- Check power supply functionality
Access gate limit switch
Good(
) / Not Good(
)
Electrical panel
Good(
) / Not Good(
)
- Check functionality and condition
Right side consol
Good(
) / Not Good(
)
- Check wire termination
Left side consol
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
2. Electrical system
3. Selector switch and push button
4. Indicator light - Check functionality and condition - Check wire termination
5. Consol - Check wire termination and condition
Right side consol
Good(
) / Not Good(
)
Left side consol
Good(
) / Not Good(
)
Siren
Good(
) / Not Good(
)
6. Foot siren - Check functionality and condition - Check wire termination
7. Structure
Cabin door
Good(
) / Not Good(
)
- Check structure condition
Access gate
Good(
) / Not Good(
)
- Check wind screen/ glass condition
All bushings
Good(
) / Not Good(
)
Handrail
Good(
) / Not Good(
)
Access ladder
Good(
) / Not Good(
)
Support beam
Good(
) / Not Good(
)
Platform
Good(
) / Not Good(
)
Amplifier and speaker
Good(
) / Not Good(
)
Operator seat
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
8. Public access (PA) system - Check functionality and condition - Check wire termination
9. Operator seat - Check functionality and condition
10. Housekeeping
SUPPORTING DOCUMENT
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#REF!
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#REF!
Effective Date
#REF!
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29 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 3 of 3
490 - AIR-CONDITIONER INSPECTION
Description
Location
Observation
Remark
1. Compressor - Check structure and condition
Control room
Good(
) / Not Good(
)
- Check wire termination and functionality
Operator cabin
Good(
) / Not Good(
)
- Check gas quantity and any leakage
Checker cabin
Good(
) / Not Good(
)
Note : Fill up where applicable
2. Indoor unit - Check structure and condition
Control room
Good(
) / Not Good(
)
- Check wire termination and functionality
Operator cabin
Good(
) / Not Good(
)
Checker cabin
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
3. Tubing and fitting - Check tube condition and any leakage
4. Mechanical part - Check blower motor mounting condition - Check belting condition - Check cleanliness
5. Housekeeping
500 - SOFTWARE AND PROGRAM MONITORING
Please see attachment (if any)
General Remark :
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#REF!
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#REF!
Effective Date
#REF!
Page
30 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
510 - MAIN HOIST SYSTEM GREASING
Description
Location
Observation
Remark
1. Main hoist system - Pump-in new grease into greasing point Note : Fill up where applicable
2. Housekeeping
520
Headblock sheave
Done(
) / Not Done(
)
Headblock twistlock
Done(
) / Not Done(
)
Backreach-main hoist sheave
Done(
) / Not Done(
)
Trolley platform-main hoist sheave
Done(
) / Not Done(
)
Main hoist drum sheave
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
- TROLLEY SYSTEM GREASING
Description
Location
Observation
Remark
1. Trolley system
- Pump-in new grease into greasing point Note : Fill up where applicable
2. Housekeeping
530
Trolley sheave
Done(
) / Not Done(
)
Trolley floating shaft
Done(
) / Not Done(
)
Trolley plumber block
Done(
) / Not Done(
)
Catenary wheel
Done(
) / Not Done(
)
Catenary sheave
Done(
) / Not Done(
)
Catenary McGill guide roller
Done(
) / Not Done(
)
Backreach-ca tenary sheave
Done(
) / Not Done(
)
Backreach rope tensioner bearing
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
- BOOM SYSTEM GREASING
Description
Location
Observation
Remark
1. Boom system - Pump-in new grease into greasing point
Boom drum
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
2. Housekeeping
General Remark :
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#REF!
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#REF!
Effective Date
#REF!
Page
31 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 1 of 3
540 - PASSENGER LIFT INSPECTION
Description
Location
Observation
Remark
1. Guide rail All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
Top of cabin
Good(
) / Not Good(
)
All brakes
Good(
) / Not Good(
)
All floors
Good(
) / Not Good(
)
All push buttons
Good(
) / Not Good(
)
Power cable
Good(
) / Not Good(
)
Carrier
Good(
) / Not Good(
)
Inside carrier
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check buffer spring and rail condition - Check mounting condition
2. Gear - Check rack and pinion gear condition
3. Reduction gear box - Check gearbox condition - Check mounting condition
4. Motor - Check casing and mounting condition
5. Brake - Check functionality and brake condition
6. Cabin level - Check setting on each floor level
7. Push button - Check functionality and condition
8. Cable - Check cable insulation and condition - Check protection rubber and mounting condition
9. Carrier structure - Check door and roof door condition - Check ladder condition
10. Intercomm - Check condition and functionality
11. Housekeeping
550 - FIRE ALARM SYSTEM INSPECTION
Description
Location
Observation
Remark
1. Electrical part - Check AC power LED light up
Machinery house
- Determine standby battery condition ( 25.5 ≤ x ≤ 26.6 Vdc )
- Zone 1
Good(
) / Not Good(
- Check any alarm LED light up from panel
- Zone 2
Good(
) / Not Good(
)
- Zone 3
Good(
) / Not Good(
)
- Fire, Fault, Off, Extinguisher release, Walk test, External acoustic alarm off, CPU fault, Power supply fault. - Any fault message on the display (Stated the fault message) Note : Fill up where applicable
)
- Zone 4
Good(
) / Not Good(
)
- Main
Good(
) / Not Good(
)
- Charger
Good(
) / Not Good(
)
- Evacuate
Good(
) / Not Good(
)
Good(
) / Not Good(
)
2. Mechanical Part - Visual Check for cylinder pressure gauge reading (±170 bar for 225 bar system) - Examine cylinder valve and hoses for sign of damage, wear or leakage - Inspect all piping & nozzles for any sign damage & leakage Note : Fill up where applicable
Good(
) / Not Good(
)
Good(
) / Not Good(
)
SUPPORTING DOCUMENT
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#REF!
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#REF!
Effective Date
#REF!
Page
32 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 2 of 3
560 - MAINTENANCE HOIST CRANE INSPECTION
Description
Location
Observation
Remark
1. Limit switch and functional test - Hoist up stop
Machinery house
Good(
) / Not Good(
- Hoist up slow down
Machinery house
Good(
) / Not Good(
) )
- Hoist down stop
Machinery house
Good(
) / Not Good(
)
- Trolley forward stop
Machinery house
Good(
) / Not Good(
)
- Trolley forward slow down
Machinery house
Good(
) / Not Good(
)
- Trolley backward stop
Machinery house
Good(
) / Not Good(
)
- Trolley backward slow down
Machinery house
Good(
) / Not Good(
)
- Gantry right stop
Machinery house
Good(
) / Not Good(
)
- Gantry right slow down
Machinery house
Good(
) / Not Good(
)
- Gantry left stop
Machinery house
Good(
) / Not Good(
)
- Gantry left slow down
Machinery house
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
Rubber buffer
Good(
) / Not Good(
)
Hook block
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
Electrical box
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Control console - Check functionality and condition - Check structure
3. Structure - Check structure condition - Check hook and latch condition
4. Wire rope and turn buckle - Check loosed nut and wire rope condition - Check any rusty
5. Electrical part - Check wire termination and contactor condition 6. Housekeeping
570 - AIR COMPRESSOR INSPECTION
Description
Location
Observation
Remark
1. Compressor - Check oil level sufficient, air filter, V-belt, pressure gauge,
Machinery house
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
safety valve, piping and mounting condition - Check any abnormal sound or vibration
2. Pressure Switch - Check pressure setting Note : Cut in: 9.9 kg/cm2 & Cut out: 8.0 kg/cm2 - Adjusting screw locknut and check wire termination
3. Motor - Check mounting and any abnormal sound
4. Housekeeping
General Remark :
SUPPORTING DOCUMENT
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#REF!
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#REF!
Effective Date
#REF!
Page
33 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 3 of 3
580
- QC CHECKER CABIN INSPECTION
Description
Location
Observation
Remark
1. Socket & power supply - Check mounting and condition
2. Check lighting condition and functionality
All location
Good(
) / Not Good(
)
Cabin ceiling
Good(
) / Not Good(
)
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
3. Intercomm - Check condition and functionality
4. Structure - Check mounting and condition - Check door and glass
5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
#REF!
Revision No.
#REF!
Effective Date
#REF!
Page
34 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM: Page 1 of 1
590
- BOOM FORESTAY INSPECTION
Description
Location
Observation
Remark
1. Bushing - Check abnormal sound and vibration
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All supports
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Structure and mounting - Check condition and mounting
3. Rest support - Check forestay rest support condition
4. Boom buffer - Check condition and mounting
5. Housekeeping
600
- BOOM SHEAVE INSPECTION
Description
Location
Observation
Remark
1. Check bearing condition
All sheaves
Good(
) / Not Good(
)
2. Check grove condition
All sheaves
Good(
) / Not Good(
)
All sheaves
Good(
) / Not Good(
)
All sheaves
Done(
) / Not Done(
)
3. Structure - Check mounting and condition
4. Housekeeping
610
- BOOM CABIN INSPECTION
Description
Location
Observation
Remark
1. Indicator bulb - Check condition and functionality
2. Check lighting condition and functionality
All indicators bulbs
Good(
) / Not Good(
)
Cabin ceiling
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Done(
) / Not Done(
)
3. Structure - Check mounting and condition - Check door and glass
4. Intercomm - Check condition and functionality
5. Housekeeping
General Remark :
All location
SUPPORTING DOCUMENT
Document No.
#REF!
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#REF!
Effective Date
#REF!
Page
35 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
620
- GANTRY SYSTEM GREASING
Description
Location
Observation
Remark
1. Gantry system - Pump-in new grease into greasing point
2. Housekeeping
630
All boggies
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
- BOOM SYSTEM GREASING
Description
Location
Observation
Remark
1. Boom system - Pump-in new grease into greasing point
2. Housekeeping
All boom sheaves
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
640 - MAIN HOIST WIRE ROPE LUBRICATION
Description
Location
Observation
Remark
1. Main hoist wire rope - Check condition and lubricate wire rope
2. Housekeeping
All main hoist wire ropes
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
650 - TROLLEY WIRE ROPE LUBRICATION
Description
Location
Observation
Remark
1. Trolley wire rope - Check condition and lubricate wire rope
All trolley wire ropes
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
2. Housekeeping
660 - BOOM WIRE ROPE LUBRICATION
Description
Location
Observation
Remark
1. Boom wire rope - Check condition and lubricate wire rope
2. Housekeeping
All boom wire ropes
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
670 - CATERNARY WIRE ROPE LUBRICATION
Description
Location
Observation
Remark
1. Catenary wire rope - Check condition and lubricate wire rope
All caternary wire ropes
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
2. Housekeeping
SUPPORTING DOCUMENT
Document No.
#REF!
Revision No.
#REF!
Effective Date
#REF!
Page
36 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 1 of 1
680
- MAIN CABLE REEL INSPECTION
Description
Location
Observation
Remark
1. Motor - Check mounting and condition
Main cable reel motor
Good(
) / Not Good(
)
Main power cable
Good(
) / Not Good(
)
All mounting
Good(
) / Not Good(
)
Good(
) / Not Good(
)
2. Main cable - Check cable condition
3. Structure - Check mounting and condition
4. Slip ring - Check slip rings condition
5. Gearbox - Check gearbox oil condition
Good(
) / Not Good(
)
- Check mounting and condition
Good(
) / Not Good(
)
- Check any abnormal sound
Good(
) / Not Good(
)
Done(
) / Not Done(
)
6. Housekeeping
General Remark :
All location
SUPPORTING DOCUMENT
Document No.
#REF!
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#REF!
Effective Date
#REF!
Page
37 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
690 - BOOM BACKSTAY GREASING
Description
Location
Observation
Remark
1. Boom backstay - Pump-in new grease into greasing point
All greasing points
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
2. Housekeeping
700 - KBT COUPLING GREASING
Description
Location
Observation
Remark
1. KBT coupling - Pump-in new grease into greasing point
Done(
) / Not Done(
)
Done(
) / Not Done(
)
Note : Fill up where applicable Please see attachment (No. :
2. Housekeeping
General Remark :
)
All location
SUPPORTING DOCUMENT
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#REF!
Revision No.
#REF!
Effective Date
#REF!
Page
38 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AC/DC MEGGER : Page 1 of 1
710 - MAIN HOIST AC & DC MOTOR INSULATION READING
Note : Fill up where applicable Please see attachment (No. :
)
720 - TROLLEY AC & DC MOTOR INSULATION READING
Note : Fill up where applicable Please see attachment (No. :
)
730 - BOOM AC & DC MOTOR INSULATION READING
Note : Fill up where applicable Please see attachment (No. :
)
740 - GANTRY AC & DC MOTOR INSULATION READING
Note : Fill up where applicable Please see attachment (No. :
General Remark :
)
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
1 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST MONTH / YEAR
:
CRANE NUMBER
:
JOB NUMBER
:
W.O. NUMBER
:
DATE /TIME START : DATE/TIME END
:
HOUR METER READING : CRANE
:
MAIN HOIST
:
LAND SIDE (FOR DUAL HOIST CRANE)
SEA SIDE (FOR DUAL HOIST CRANE)
TROLLEY
:
GANTRY
:
BOOM
:
PM CHECKLIST TYPE : Please tick ( X ) where applicable :
MONTHLY PM
:
Page 1 to page 30
(
)
QUARTERLY PM
:
Page 1, page 31 to page 36
(
)
SEMI-ANNUALLY PM :
Page 1, page 37 to page 38
(
)
ANNUALLY PM
Page 1 to page 38
(
)
SYSTEM :
:
PREPARED BY :
SIGNATURE :
MAIN HOIST SYSTEM Date :
TROLLEY SYSTEM Date :
GANTRY SYSTEM Date :
BOOM SYSTEM Date :
AUXIALLARY SYSTEM Date :
GREASING Date :
VERIFIED BY :
SIGNATURE :
Date :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
2 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 1 of 8
10
- MAIN HOIST BRAKE
10.1 - SERVICE BRAKE
Description
Location
Observation
Remark
B rake #1 (Height : _________ mm)
Good(
) / Not Go od(
)
- Inspect stroke indicator setting and manual release
B rake #2 (Height : _________ mm)
Good(
) / Not Go od(
)
Note : Fill up where applicable
B rake #3 (Height : _________ mm)
Good(
) / Not Go od(
)
B rake #4 (Height : _________ mm)
Good(
) / Not Go od(
)
1. Reserve stroke height (10 mm)
. ra ng orque
Brake #1 (Torque : ________________ Nm)
Good(
) / Not Good(
)
- Inspect setting and mechanical component
Brake #2 (Torque : ________________ Nm)
Good(
) / Not Good(
)
Note : IMPSA-A :≥ 15.75kNm, NOELL/MITSUI : ≥ 14.85kNm,
Brake #3 (Torque : ________________ Nm)
Good(
) / Not Good(
)
Brake #4 (Torque : ________________ Nm)
Good(
) / Not Good(
)
All brakes
Good(
) / Not Good(
)
IMPSA-B : 27kNm, ZPMC-A : 12.6kNm ZPMC-A : ≥ 14.85kNm, ZPMC-C : 19kNm
3. Air gap - Check any rubbing
Brake #1 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
- Inspect pad and disc
Brake #1 LHS : ______mm
Good(
) / Not Good(
)
- Check and clean disc surface
Brake #2 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Note : Fill up where applicable
Brake #2 LHS : ______mm
Good(
) / Not Good(
)
All cranes (Pad : ≥ 5 mm, Disc : ≥ 27 mm)
Brake #3 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
ZPMC-B (Pad : ≥ 3 mm, Disc :≤1.0mm wear)
Brake #3 LHS : ______mm
Good(
) / Not Good(
)
ZPMC-C (Pad : > 3 mm, Disc wear more than 20%)
Brake #4 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #4 LHS : ______mm
Good(
) / Not Good(
)
4. Brake pad and disc
Brake #1
Good(
) / Not Good(
)
- Check one way bearing and adjusting nut condition
Brake #2
Good(
) / Not Good(
)
- Check gap AMC to catched plate
Brake #3
Good(
) / Not Good(
)
- Check adjustment AWC pin drive
Brake #4
Good(
) / Not Good(
)
Brake #1
Good(
) / Not Good(
)
Brake #2
Good(
) / Not Good(
)
Brake #3
Good(
) / Not Good(
)
Brake #4
Good(
) / Not Good(
)
All servolifters
Good(
) / Not Good(
)
Good(
) / Not Good(
)
5. Check AWC condition
6. Check wedge and shackle kit Note : Fill up where applicable
7. Servolifter / Thruster - Inspect oil, electrical and mechanical part
8. Structure - Check pivot pin, linkage and mounting
9. Limit Switch - Check setting and functionality Note : Fill up where applicable 10. Housekeeping
General Remark :
a. Brake manual release
Good(
) / Not Good(
)
b. Brake release
Good(
) / Not Good(
)
c. Brake pad wear
Good(
) / Not Good(
)
Done(
) / Not Done(
)
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
3 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 2 of 8
10.2 - EMERGENCY BRAKE ( MAIN & AUX)
Description
1. Hydraulic Tank
Location
Observation
Remark
Mechinery House
- Check oil condition
Good(
) / Not Good(
)
- Check oil level
Good(
) / Not Good(
)
- Check working pressure (150 -180 bar)
Good(
) / Not Good(
)
- Check tank condition
Good(
) / Not Good(
)
- Check hoses leakage
Good(
) / Not Good(
)
- Check solenoid coil & dim plugs
Good(
) / Not Good(
)
- Check valve leakage & functions
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
2. Hydraulic cylinder and block
3. Proximity sensor - Check setting and functionality Note : Fill up where applicable
4. Motor & Electrical Components - Check electrical termination - Measure Motor demands
Phase 1: _______(A) Phase 2: _______(A) Phase 3: _______(A)
5. Brake pad and disc - Inspect pad and disc (Pad : ≤ 8 mm, Disc : ≥ 28 mm)
Disc Plate#1 RHS : ______mm
Good(
) / Not Good(
)
- Check and clean disc surface
Disc Plate#1 LHS : ______mm
Good(
) / Not Good(
)
Disc Drum#1 RHS : ______mm
Good(
) / Not Good(
)
Disc Drum #1 LHS : ______mm
Good(
) / Not Good(
)
Disc Plate#2 RHS : ______mm
Good(
) / Not Good(
)
Disc Plate #2 LHS : ______mm
Good(
) / Not Good(
)
Disc Drum#2 RHS : ______mm
Good(
) / Not Good(
)
Disc Drum #2 LHS : ______mm
Good(
) / Not Good(
)
Done(
) / Not Done(
)
Note : Fill up where applicable
6. Housekeeping
General Remark :
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
4 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 3 of 8
20 - MAIN HOIST GEARBOX / REDUCER
Description
Location
Observation
Remark
1. Gearbox oil - Inspect oil level and oil condition Note : Fill up where applicable
Gearbox #1
Good(
) / Not Good(
)
Gearbox #2
Good(
) / Not Good(
)
Gearbox #1
Good(
) / Not Good(
)
Gearbox #2
Good(
) / Not Good(
)
2. Structure - Inspect mounting bolts tightness and crack Note : Fill up where applicable 3. Bearing - Inspect abnormal sound Note : Fill up where applicable 4. Temperature (40 ~ 60 degree) Note : Fill up where applicable 5. Housekeeping
Gearbox #1
Good(
) / Not Good(
)
Gearbox #2
Good(
) / Not Good(
)
Gearbox #1 : _________degree
Good(
) / Not Good(
)
Gearbox #2 : _________degree
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
30 - MAIN HOIST DRIVE & BLOWER MOTOR
Description
1. Sound inspection Note : Fill up where applicable
2. Check heater Note : For DC motor only
Location
Observation
Remark
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
Motor #3
Good(
) / Not Good(
)
Motor #4
Good(
) / Not Good(
)
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
3. Visual check - Check coupling motor & gear box (Bush Coupling)
Motor #1
Good(
) / Not Good(
)
- Check terminations
Motor #2
Good(
) / Not Good(
)
- Check mounting bolts and frame
Motor #3
Good(
) / Not Good(
)
Motor #4
Good(
) / Not Good(
)
Note : Fill up where applicable
Motor #1
Good(
) / Not Good(
)
- Check rotation
Motor #2
Good(
) / Not Good(
)
- Check running cond
Motor #3
Good(
) / Not Good(
)
- Measure motor demands
Motor #4
Good(
) / Not Good(
)
4. Check blower motor cond.
- Check coupling condition
5. Emergency Motor - Check coupling condition & chain link
Motor #1
Good(
) / Not Good(
)
- Check limit switch working condition
Motor #2
Good(
) / Not Good(
)
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
Motor #3
Good(
) / Not Good(
)
Motor #4
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
6. Air Filter - Check clealiness
7. Housekeeping
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
5 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 4 of 8
40 - MAIN HOIST WIRE ROPE INSPECTION
Description
Location
Observation
Remark
1. Visual check - Check broken strands, deformation and kinks
Drum
Good(
) / Not Good(
- Diameter (NOELL/ZPMC-A : 26.2mm~28.0mm)
Backreach
Good(
) / Not Good(
)
- Diameter (IMPSA : 26.7mm~28.5mm)
Trolley platform
Good(
) / Not Good(
)
Good(
) / Not Good(
)
- Diameter (ZPMC-C : 32.00mm~29.76mm)
Main Girder Area (5 mtr before Joint)
Good(
) / Not Good(
)
- Broken strands (<18 wires)
Boom Girder Area (5 mtr after Joint)
Good(
) / Not Good(
)
- Diameter (MITSUI : 26.2mm~23.3mm)
Headblock
)
Note : Fill up where applicable Length #1
Good(
) / Not Good(
)
- Check loosed nut and condition
Length #2
Good(
) / Not Good(
)
- Check installation
Length #3
Good(
) / Not Good(
)
Length #4
Good(
) / Not Good(
)
2. Clips and Clamp
3. Check for lubrication - Check rusty
Length #1
Good(
) / Not Good(
)
Length #2
Good(
) / Not Good(
)
Length #3
Good(
) / Not Good(
)
Length #4
Good(
) / Not Good(
)
All rollers and plates
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
4. Support roller and plate - Check condition 5. Housekeeping
50 - MAIN HOIST WIRE ROPE DRUM INSPECTION
Description
Location
Observation
Remark
1. Check wire rope anchor
All drums
Good(
) / Not Good(
)
2. Check bearing any abnormal noise
All drums
Good(
) / Not Good(
)
3. Check groove surface condition
All drums
Good(
) / Not Good(
)
4. Check structure and mounting
All drums
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
6 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 5 of 8
60 - MAIN HOIST SHEAVE AND BEARING INSPECTION
Description
1. Check groove condition any damaged or rope trace mark Note : Fill up where applicable
2. Check locking / keeper plate condition Note : Fill up where applicable
3. Check bearing condition Note : Fill up where applicable
4. Housekeeping
Location
Observation
Remark
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Headblock
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Headblock
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Headblock
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
70 - MAIN HOIST MOTOR AND GEARBOX COUPLING INSPECTION
Description
1. Check abnormal sound
Location
Observation
Remark
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Check coupling cover Note : Fill up where applicable
3. Check rubber insert condition Note : Fill up where applicable
4. Structure - Check bolt tightness and condition 5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
7 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 6 of 8
80 - MAIN HOIST CAM SWITCH INSPECTION
Description
Location
Observation
Remark
1. Cable termination - Check cable damage and breakage at cable lugs
Main hoist drum
Good(
) / Not Good(
)
All switches
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
Main hoist drum
Good(
) / Not Good(
)
2. Cam switch functionality - Function test
3. Cam switch coupling tightness - Check bolt tightness Note : Fill up where applicable 4. Check cam switch set - Check mounted bolt tightness
5. Cam Switch Gear Reducer - Check oil/lubricant condition
Main hoist drum
- Check oil/lubricant level
6. Housekeeping
All location
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Done(
) / Not Done(
)
90 - MAIN HOIST LIMIT SWITCH (STOP UP/OVER TRAVEL) INSPECTION
Description
Location
Observation
Remark
1. Cable / conduit - Check cable condition, insulation and cable lug
Trolley platform / trolley house
Good(
) / Not Good(
)
Trolley platform / trolley house
Good(
) / Not Good(
)
Trolley platform / trolley house
Good(
) / Not Good(
)
Spreader cable / headblock
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Limit switch - Check positioning, rusty, functionality and mounting
3. Counter weight - Check condition Note : Fill up where applicable
4. Striker - Check condition Note : Fill up where applicable 5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
8 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 7 of 8
100 - MAIN HOIST ENCODER INSPECTION
Description
Location
Observation
Remark
1. Coupling - Check mounting, rusty, alignment and sprider wear
Main hoist motor and drum
Good(
) / Not Good(
)
Main hoist drum
Good(
) / Not Good(
)
Main hoist drum
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable 2. Driven belt / driven chain / Reducer - Check belting condition and any crack Note : Fill up where applicable 3. Electrical Termination - Check cable connection Note : Fill up where applicable
5. Housekeeping
110 - MAIN HOIST OVER SPEED DETECTOR INSPECTION
Description
Location
Observation
Remark
1. Cable termination - Check cable damage and breakage at cable lugs
Main hoist drum
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Coupling tightness - Check bolt tightness
4. Housekeeping
120 - SPREADER CABLE REEL INSPECTION
Description
Location
Observation
Remark
Trolley platform / trolley house 1. Spreader drum / reel - Check drum condition
Drum Reel # 1
Good(
) / Not Good(
)
- Check cable condition & arrangement
Drum Reel # 2
Good(
) / Not Good(
)
Drum Reel # 1
Good(
) / Not Good(
)
2. Driven belt / driven chain (cam switch) - Check belting condition and any crack Note : Fill up where applicable
Drum Reel # 2
3. Magnetic Clutch - Check bearings condition
Motor# 1
Good(
) / Not Good(
)
- Check air gap
Motor# 2
Good(
) / Not Good(
)
Motor# 3
Good(
) / Not Good(
)
Motor# 4
Good(
) / Not Good(
)
4. Electrical - Check cable connection and slip ring carbon brushes - Check short length cable and junction box
Trolley platform / trolley house
Good(
) / Not Good(
)
Headblock
Good(
) / Not Good(
)
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
9 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 8 of 8
Description
Location
Observation
Remark
5. Limit switch - Check limit switch condition
Trolley platform / trolley house
Good(
) / Not Good(
)
Headblock
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
6. Absorber - Check condition 7. Housekeeping
130 - SPREADER HEADBLOCK - LAND SIDE INSPECTION
Description
Location
Observation
Remark
1. Twistlock - Check gap, lock pin and condition
All twistlocks
Good(
) / Not Good(
)
- Check headblock connected cond.
Headblock lock/unlock lever
Good(
) / Not Good(
)
- Check headblock anchor sensor cond.
Headblock lock/unlock lever
Good(
) / Not Good(
)
2. Switches
3. Structure & Hydraulic System - Check condition, ladder, hand rail and grating
Good(
) / Not Good(
)
- Check hyd. Tank oil level
Good(
) / Not Good(
)
Done(
) / Not Done(
)
- Check hyd. Hoses - Check hyd. Valves
All location
140 - TRIM, LIST AND SKEW (TLS) SYSTEM INSPECTION
Description
Location
Observation
Remark
1. Power pack - Check oil level, condition and cleanliness - Check working pressure (160±10 psi) - Check hose, valve and piping
Backreach / TLS platform / trolley house
Good(
) / Not Good(
)
Pressure : _________ psi
Good(
) / Not Good(
)
Backreach / TLS platform / trolley house
Good(
) / Not Good(
)
All cylinders
Good(
) / Not Good(
)
All motors and pumps
Good(
) / Not Good(
)
All control boxes
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Hydraulic cylinder - Check oil leak, guide roller and condition
3. Positioner sensor - Check wire string, mounting and crack
4. Motor and pump - Check abnormal sound, overheating, and cover - Check electrical connection
5. TLS control panel - Check wire termination, conduit and DC supply - Check door and lock condition 6. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
10 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 1 of 8
150
- TROLLEY BRAKE INSPECTION
Description
1. Reserve stroke height (10 mm) - Inspect stroke indicator setting and manual release Note : Fill up where applicable
.
Location
Observation
Remark
B rake #1 (Height : _________ mm)
Go od(
) / Not Go od(
)
B rake #2 (Height : _________ mm)
Go od(
) / Not Go od(
)
B rake #3 (Height : _________ mm)
Go od(
) / Not Go od(
)
B rake #4 (Height : _________ mm)
Go od(
) / Not Go od(
)
Brake #1 (Torque : ________________ Nm)
Good(
) / Not Good(
)
- Inspect setting and mechanical component
Brake #2 (Torque : ________________ Nm)
Good(
) / Not Good(
)
Note : IMPSA-A : ≥ 977Nm, NOELL /MITSUI/ZPMC-A : ≥ 1890Nm
Brake #3 (Torque : ________________ Nm)
Good(
) / Not Good(
)
IMPSA-B : ≥ 977Nm , ZPMC-B : ≥ 5175 Nm, ZPMC-C : 5500Nm
Brake #4 (Torque : ________________ Nm)
Good(
) / Not Good(
)
All brakes
Good(
) / Not Good(
)
Brake #1 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #1 LHS : ______mm
Good(
) / Not Good(
)
ZPMC-C: Disk wear >20% from 30mm, Pad >3mm
Brake #2 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
ZPMC(Pad : ≥ 3 mm, Disc : ≤ 1.0mm wear on each side)
Brake #2 LHS : ______mm
Good(
) / Not Good(
)
Brake #3 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #3 LHS : ______mm
Good(
) / Not Good(
)
Brake #4 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #4 LHS : ______mm
Good(
) / Not Good(
)
Brake #1
Good(
) / Not Good(
)
Brake #2
Good(
) / Not Good(
)
Brake #3
Good(
) / Not Good(
)
Brake #4
Good(
) / Not Good(
)
Brake #1
Good(
) / Not Good(
)
Brake #2
Good(
) / Not Good(
)
Brake #3
Good(
) / Not Good(
)
Brake #4
Good(
) / Not Good(
)
All servolifters
Good(
) / Not Good(
)
Good(
) / Not Good(
)
3. Air gap - Check any rubbing
4. Brake pad and disc - Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm)
- Check and clean disc surface Note : Fill up where applicable
5. Check AWC condition - Check one way bearing and adjusting nut condition Note : Fill up where applicable
6. Check wedge and shackle kit Note : Fill up where applicable
7. Servolifter / Thruster - Inspect oil, electrical and mechanical part
8. Structure - Check pivot pin, linkage and mounting
9. Limit Switch - Check setting and functionality Note : Fill up where applicable 10. Housekeeping
General Remark :
a. Brake manual release
Good(
) / Not Good(
)
b. Brake release
Good(
) / Not Good(
)
c. Brake pad wear
Good(
) / Not Good(
)
Done(
) / Not Done(
)
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
11 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 2 of 8
160
- TROLLEY GEARBOX INSPECTION
Description
Location
Observation
Remark
Gearbox #1
Good(
) / Not Good(
)
- Inspect oil level and oil condition
Gearbox #2
Good(
) / Not Good(
)
Note : Fill up where applicable
Gearbox #3
Good(
) / Not Good(
)
Gearbox #4
Good(
) / Not Good(
)
1. Gearbox oil
2. Structure - Inspect mounting bolts tightness and crack Note : Fill up where applicable
3. Bearing - Inspect abnormal sound Note : Fill up where applicable
4. Temperature (40 ~ 60 degree) Note : Fill up where applicable
5. Housekeeping
170
Gearbox #1
Good(
) / Not Good(
)
Gearbox #2
Good(
) / Not Good(
)
Gearbox #3
Good(
) / Not Good(
)
Gearbox #4
Good(
) / Not Good(
)
Gearbox #1
Good(
) / Not Good(
)
Gearbox #2
Good(
) / Not Good(
)
Gearbox #3
Good(
) / Not Good(
)
Gearbox #4
Good(
) / Not Good(
)
Gearbox #1 : _________degree
Good(
) / Not Good(
)
Gearbox #2 : _________degree
Good(
) / Not Good(
)
Gearbox #3 : _________degree
Good(
) / Not Good(
)
Gearbox #4 : _________degree
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- TROLLEY MOTOR INSPECTION
Description
Location
Observation
Remark
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
Motor #3
Good(
) / Not Good(
)
Motor #4
Good(
) / Not Good(
)
Note : For DC motor only
Motor #1
Good(
) / Not Good(
)
Note : Fill up where applicable
Motor #2
Good(
) / Not Good(
)
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
Motor #3
Good(
) / Not Good(
)
Motor #4
Good(
) / Not Good(
)
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
1. Sound inspection Note : Fill up where applicable
2. Check heater condition
3. Visual check - Check armature winding for burn marks, scratches and damages (For DC motor only) - Check structure and wire termination Note : Fill up where applicable
4. Check motor in running condition for sparks Note : For DC motor only
5. Emergency motor - Check coupling condition
Motor #1
Good(
) / Not Good(
)
- Check limit switch working condition
Motor #2
Good(
) / Not Good(
)
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
12 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 3 of 8
Description
6. Carbon brush and holder - Check length and condition Note : For DC motor only
Location
Remark
Motor #1 - Top (3 pcs)
Good(
) / Not Good(
)
Motor #1 - Bottom (3 pcs)
Good(
) / Not Good(
)
Motor #1 - Right (3 pcs)
Good(
) / Not Good(
)
Motor #1 - Left (3 pcs)
Good(
) / Not Good(
)
Motor #2 - Top (3 pcs)
Good(
) / Not Good(
)
Motor #2 - Bottom (3 pcs)
Good(
) / Not Good(
)
Motor #2 - Right (3 pcs)
Good(
) / Not Good(
)
Motor #2 - Left (3 pcs)
Good(
) / Not Good(
)
All location
7. Housekeeping
Observation
Done(
) / Not Done(
)
180 - TROLLEY WIRE ROPE INSPECTION
Description
Location
Observation
Remark
1. Visual check - Check broken strands, deformation and kinks
Drum
Good(
) / Not Good(
- Diameter (2 6.2mm~mm)
Backreach
Good(
) / Not Good(
)
- Broken strands (<18 wires)
Trolley platform
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Length #1
Good(
) / Not Good(
)
Length #2
Good(
) / Not Good(
)
Note : Fill up where applicable
2. Clips and turnbuckles - Check loosed nut and condition 3. Check for lubrication - Check rusty
)
Length #1
Good(
) / Not Good(
)
Length #2
Good(
) / Not Good(
)
All rollers and plates
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
4. Support roller and plate - Check condition 5. Housekeeping
190 - TROLLEY WIRE ROPE DRUM INSPECTION
Description
Location
Observation
Remark
1. Check wire rope anchor
All drums
Good(
) / Not Good(
)
2. Check bearing any abnormal noise
All drums
Good(
) / Not Good(
)
3. Check groove surface condition
All drums
Good(
) / Not Good(
)
4. Check structure and mounting
All drums
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
13 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 4 of 8
200 - TROLLEY SHEAVE AND BEARING INSPECTION
Description
1. Check groove condition any damaged or rope trace mark Note : Fill up where applicable
2. Check locking / keeper plate condition Note : Fill up where applicable
3. Check bearing condition Note : Fill up where applicable
4. Housekeeping
Location
Observation
Remark
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
210 - TROLLEY MOTOR AND GEARBOX COUPLING INSPECTION
Description
1. Check abnormal sound
Location
Observation
Remark
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
2. Check coupling cover Note : Fill up where applicable
3. Check rubber insert condition Note : Fill up where applicable
4. Structure - Check bolt tightness and condition
220
- TROLLEY WHEEL INSPECTION
Description
1. Wheel - Check wheel bearing condition and abnormal sound
2. Structure - Check wheel flange cracks or damages and condition
3. Guide roller - Check bearing and guide roller condition
Location
Observation
Remark
Wheel #1
Good(
) / Not Good(
)
Wheel #2
Good(
) / Not Good(
)
Wheel #3
Good(
) / Not Good(
)
Wheel #4
Good(
) / Not Good(
)
Wheel #1
Good(
) / Not Good(
)
Wheel #2
Good(
) / Not Good(
)
Wheel #3
Good(
) / Not Good(
)
Wheel #4
Good(
) / Not Good(
)
Wheel #1
Good(
) / Not Good(
)
Wheel #2
Good(
) / Not Good(
)
Wheel #3
Good(
) / Not Good(
)
Wheel #4
Good(
) / Not Good(
)
Document No.
SUPPORTING DOCUMENT
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
14 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST TROLLEY : Page 5 of 8
Description
4. Floating shaft - Check coupling condition and bolt tighness Note : Fill up where applicable
5. Plumber block - Chek abnormal sound Note : Fill up where applicable
6. Housekeeping
230
Location
Observation
Remark
Floating shaft LHSS
Good(
) / Not Good(
)
Floating shaft LHLS
Good(
) / Not Good(
)
Floating shaft RHLS
Good(
) / Not Good(
)
Floating shaft RHSS
Good(
) / Not Good(
)
Plumber block LHSS
Good(
) / Not Good(
)
Plumber block LHLS
Good(
) / Not Good(
)
Plumber block RHLS
Good(
) / Not Good(
)
Plumber block RHSS
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- TROLLEY RAIL INSPECTION
Description
Location
Observation
Remark
1. Trolley rail structure
- Check greasy or oily
All
Good(
) / Not Good(
- Check rail clip, bolt and nut
All
Good(
) / Not Good(
)
- Check welded part cracked or chipped
All
Good(
) / Not Good(
)
- Check side plate bolt tightness
Boom joint
Good(
) / Not Good(
)
- Check trolley rail gap
Boom joint
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Housekeeping
)
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
15 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 6 of 8
240 - TROLLEY LIMIT SWITCH INSPECTION
Description
Location
Observation
Remark
1. Cable and conduit Good(
) / Not Good(
)
All limit switches
Good(
) / Not Good(
)
All flag sensors
Good(
) / Not Good(
)
- Check insulation, termination and condition
2. Limit switch - Check condtion, mounting and functionality 3. Flag sensor - Check condtion, mounting and functionality
4. Slowdown magnet - Check condtion, mounting and functionality 5. Housekeeping
250
Boom tip
Good(
) / Not Good(
)
Backreach
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- TROLLEY ENCODER INSPECTION
Description
Location
Observation
Remark
1. Coupling - Check mounting, rusty, alignment and sprider wear
Trolley motor
Good(
) / Not Good(
)
Trolley motor
Good(
) / Not Good(
)
Trolley LS LHS
Good(
) / Not Good(
)
Trolley motor
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable 2. Electrical - Check cable connection
3. Structure - Check mounting, wheel and bearing condition Note : Fill up where applicable 4. Encoder sensor - Check sensor surface and condition
3. Housekeeping
260
- TROLLEY CATENARY INSPECTION
Description
Location
Observation
Remark
1. Wheel bearings - Check abnormal noise
All location
Good(
) / Not Good(
)
2. Trolley wheel - Check any crack or damage on wheel flange
All wheels
Good(
) / Not Good(
)
- Check wheel bracket bolts tighten
All wheel brackets
Good(
) / Not Good(
)
- Check wheel cover bolt tightness
All bolts
Good(
) / Not Good(
)
Note : Fill up where applicable 3. Sheave and bearing - Check groove condition
1. Boom tip LHS and RHS
Good(
) / Not Good(
)
- Check sheave bearing abnormal sound and condition
2. Catenary LS LHS and RHS
Good(
) / Not Good(
)
- Check locking /keeper plate bolts and nuts condition
3. Catenary SS LHS and RHS
Good(
) / Not Good(
)
4. Backreach LHS and RHS
Good(
) / Not Good(
)
Note : Fill up where applicable
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
16 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 7 of 8
Description
Location
Observation
Remark
4. Catenary wire rope - Visual check for wear, deformation and kinks Note : Fill up where applicable
1. Drive rope LHS and RHS
Good(
) / Not Good(
)
2. Tie rope LHS and RHS
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
5. Clip and turnbuckle - Check clips and turnbuckles condition Note : Fill up where applicable
6. Structure - Check catenary structure condition Note : Fill up where applicable
1. Catenary LHS
Good(
) / Not Good(
)
2. Catenary RHS
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
7. Guide roller - Check guide roller tighness and condition
8. Support roller - Check support roller, bearing and shaft condition
9. Housekeeping
270 - TROLLEY WIRE ROPE TENSIONER INSPECTION
Description
Location
Observation
Remark
1. Cylinder - Check abnormal sound and cylinder condition - Check hose and any leakage
All cylinders
Good(
) / Not Good(
)
Note : Fill up where applicable 2. Cross joint - Check vibration and any abnormal sound
All location
Good(
) / Not Good(
)
- Check bearing and shaft condition
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All limit switches
Good(
) / Not Good(
)
All limit switches
Good(
) / Not Good(
)
All power units
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
3. Sheave - Check bolt tighness, sheave and bearing condition
4. Limit switch - Check limit switch condition and functionality
5. Hydraulic power pack - Check tank, hose and fitting condition - Check any leakage and oil level
6. Power unit for motor pump - Check abnormal sound, termination and condition 7. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
17 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 8 of 8
280
- FESTOON SYSTEM INSPECTION
Description
Location
Observation
Remark
1. Festoon rail - Check deformation, dents and leveling condition
Along rails
Good(
) / Not Good(
)
All cables
Good(
) / Not Good(
)
All shackles and elastic cords
Good(
) / Not Good(
)
All bumpers
Good(
) / Not Good(
)
All rollers
Good(
) / Not Good(
)
Motor #1 and #2
Good(
) / Not Good(
)
Motor #1 and #2
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
All carrier
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Festoon cable - Check cable and cable clamp mouting condition
3. Sling shackle and elastic cord - Check any cut, broken and wear condition - Check sling shackle missing and condition
4. Festoon bumper - Check mounting and bumber condition
5. Side roller, runner wheel and anti-lift roller - Check roller condition and abnormal sound - Check mounting condition
6. Belting system - Check belting, pulley and bearing condition Note : Fill up where applicable
7. Motor (Brand : VAHLE or WAMPFLER) - Check abnormal sound and mounting condition - Check bolt tightness and motor cover condition Note : Fill up where applicable
8. Trolley festoon box - Check cable termination and slot connection condition - Check door seal condition 9. Festoon carrier - Check carrier condition
10. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
18 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 1 of 4
290
- GANTRY BRAKE INSPECTION
Description
Location
Observation
Remark
1. Gantry brake - Check wire termination - Check friction disc, stationary disc and coil assembly
All brakes
Good(
) / Not Good(
)
- Check mounting cover and silicon seal condition Note : Fill up where applicable
2. Reserve stroke height (10 mm) - Inspect stroke indicator setting and manual release Note : Fill up where applicable
Lanside Height : #1 : ______ mm
#5 : ______ mm)
Good(
) / Not Good(
)
Height : #2 : ______ mm
#6 : ______ mm)
Good(
) / Not Good(
)
Height : #3 : ______ mm
#7 : ______ mm)
Good(
) / Not Good(
)
Height : #4 : ______ mm
#8 : ______ mm)
Good(
) / Not Good(
)
Height : #1 : ______ mm
#5 : ______ mm)
Good(
) / Not Good(
)
Height : #2 : ______ mm
#6 : ______ mm)
Good(
) / Not Good(
)
Height : #3 : ______ mm
#7 : ______ mm)
Good(
) / Not Good(
)
Height : #4 : ______ mm
#8 : ______ mm)
Good(
) / Not Good(
)
Seaside
.
Lanside - Inspect setting and mechanical component
Torque : #1 : ______ Nm
#5 : ______ Nm)
Good(
) / Not Good(
)
Note : Fill up where applicable
Torque : #2 : ______ Nm
#6 : ______ Nm)
Good(
) / Not Good(
)
Torque : #3 : ______ Nm
#7 : ______ Nm)
Good(
) / Not Good(
)
Torque : #4 : ______ Nm
#8 : ______ Nm)
Good(
) / Not Good(
)
Torque : #1 : ______ Nm
#5 : ______ Nm)
Good(
) / Not Good(
)
Torque : #2 : ______ Nm
#6 : ______ Nm)
Good(
) / Not Good(
)
Torque : #3 : ______ Nm
#7 : ______ Nm)
Good(
) / Not Good(
)
Torque : #4 : ______ Nm
#8 : ______ Nm)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
IMPSA-B : > 207Nm, ZPMC-B : >320Nm, ZPMC-C : 350Nm
Seaside
4. Air gap - Check any rubbing
All brakes
Note : Fill up where applicable
5. Brake pad and disc (Landside) - Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm)
- Check and clean disc surface
Brake #1 RHS : _____mm, LHS _____mm Disc : _____mm
Note : Fill up where applicable Brake #2 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #3 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #4 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #5 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #6 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #7 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #8 RHS : _____mm, LHS _____mm Disc : _____mm
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
19 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 2 of 4
Description
Location
Observation
Remark
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
All brakes
Good(
) / Not Good(
)
All servolifters
Good(
) / Not Good(
)
- Check pivot pin, linkage, mounting and cover
All brakes
Good(
) / Not Good(
)
- Check limit switch setting and functionality
All brakes
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
6. Brake pad and disc (Seaside) - Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm)
Brake #1 RHS : _____mm, LHS _____mm Disc : _____mm
- Check and clean disc surface Note : Fill up where applicable
Brake #2 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #3 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #4 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #5 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #6 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #7 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #8 RHS : _____mm, LHS _____mm Disc : _____mm 7. Check AWC condition - Check one way bearing and adjusting nut condition Note : Fill up where applicable
8. Servolifter / Thruster - Inspect oil, electrical and mechanical part Note : Fill up where applicable
9. Structure and limit switch
10. Housekeeping
300
- GANTRY GEARBOX INSPECTION
Description
Location
Observation
Remark
1. Gearbox oil - Inspect oil level and oil condition
All gearboxes
Good(
) / Not Good(
)
All gearboxes
Good(
) / Not Good(
)
All gearboxes
Good(
) / Not Good(
)
All gearboxes
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Structure - Inspect mounting bolts tightness and crack Note : Fill up where applicable 3. Bearing - Inspect abnormal sound Note : Fill up where applicable 4. Temperature (40 ~ 60 degree) Note : Fill up where applicable 5. Coupling - Check rubber insert for coupling condition - Check circlips condition Note : Fill up where applicable 6. Housekeeping
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
20 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 3 of 4
310
- GANTRY MOTOR INSPECTION
Description
Location
Observation
Remark
1. Sound inspection - Check any abnormal sound
All motors
Good(
) / Not Good(
)
All motors
Good(
) / Not Good(
)
All motors
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Electrical - Check wire termination at motor termination box
3. Structure - Check cover, mounting and body codition 4. Housekeeping
320 - GANTRY RAIL CLAMP AND ANCHOR PIN INSPECTION
Description
Location
Observation
Remark
1. Rail clamp hydraulic unit - Check oil condition and level - Check piping, any leakage and hose condition
All units
Good(
) / Not Good(
)
All motors
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check wire termination
2. Rail clamp motor - Check any abnormal sound and vibration - Check wire termination
3. Limit switch - Check condition and functionality - Check leakage and mounting condition
4. Structure - Check any leakage and cylinder condition - Check brake shoe / lining condition - Check mounting condition Note : Fill up where applicable 5. Housekeeping
330 - GANTRY ANTI-COLLISION CRANE TO SHIP INSPECTION
Description
Location
Observation
Remark
1. Anti-collision limit switch - Check functionality
Right and left side of boom gir der
Good(
) / Not Go od(
)
Right and left side of boom gir der
Good(
) / Not Go od(
)
All location
Done(
) / Not Done(
)
- Check wire termination and micro switch condition
2. Wire rope - Check wire rope rusty and stringness Note : Fill up where applicable 3. Housekeeping
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
21 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 4 of 4
340
- GANTRY ALARM SYSTEM INSPECTION Description
Location
Observation
Remark
1. Siren - Check siren functionality and condition
All sirens
Good(
) / Not Good(
)
All warning lights
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check wire termination condition
2. Warning light - Check bulb and motor condition - Check lamp cover and mounting condition - Check wire termination condition
3. Housekeeping
350
- GANTRY WHEEL INSPECTION Description
Location
Observation
Remark
1. Wheel - Check wheel bearing condition and abnormal sound
All wheels
Good(
) / Not Good(
)
All wheels
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Structure - Check wheel flange cracks or damages and condition - Check mounting condition
3. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
22 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 1 of 5
360
- BOOM BRAKE INSPECTION
360.1 - SERVICE BRAKE
Description
1. Reserve stroke height (10 mm)
Location
Observation
Remark
B rake #1 (H eight : _________ mm)
Good(
) / Not Good(
)
Brake #1 (Torque : ________________ Nm)
Good(
) / Not Good(
)
Service brake
Good(
) / Not Good(
)
- Inspect stroke indicator setting and manual release . ra ng orque - Inspect setting and mechanical component Note : IMPSA-A : ≥ 1890Nm, NOELL/MITSUI/ZPMC -A: ≥ 14850 Nm, IMPSA-B : >7200Nm, ZPMC-B : >5940Nm, ZPMC-C: >6000Nm
3. Air gap - Check any rubbing
Brake pad RHS : ________mm
Good(
) / Not Good(
)
- Check and clean disc surface
Brake pad LHS : ________mm
Good(
) / Not Good(
)
- Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm)
Brake disc
Good(
) / Not Good(
)
Service brake
Good(
) / Not Good(
)
Service brake
Good(
) / Not Good(
)
Service brake
Good(
) / Not Good(
)
Good(
) / Not Good(
)
4. Brake pad and disc
: ________mm
ZPMC (Pad : >3.0 mm, Disc : >1.0mm wear on each side )
5. Check AWC condition - Check one way bearing and adjusting nut condition
6. Check wedge and shackle kit
7. Servolifter / Thruster - Inspect oil, electrical and mechanical part
8. Structure - Check pivot pin, linkage and mounting
9. Limit Switch - Check setting and functionality
a. Brake manual release
Good(
) / Not Good(
)
b. Brake release
Good(
) / Not Good(
)
c. Brake pad wear
Good(
) / Not Good(
)
360.2 - EMERGENCY BRAKE
Description
Location
Observation
Remark
1. Hydraulic power pack - Check oil condition and working pressure (150-180 bar)
Hydraulic oil tank
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
2. Hydraulic cylinder and block - Check leakage
3. Proximity Sensor & Motor - Check setting and functionality
All location
- Check electrical and mechanical parts
Brake #1 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
- Inspect pad and disc (Pad : ≥ 8 mm, Disc : ≥ 28 mm)
Brake #1 LHS : ______mm
Good(
) / Not Good(
)
- Check and clean disc surface
Brake #2 RHS : ______mm
Good(
) / Not Good(
)
Brake #2 LHS : ______mm
Good(
) / Not Good(
)
Brake #3 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #3 LHS : ______mm
Good(
) / Not Good(
)
Brake #4 RHS : ______mm
Good(
) / Not Good(
)
Brake #4 LHS : ______mm
Good(
) / Not Good(
)
Done(
) / Not Done(
)
4. Brake pad and disc
Note : Fill up where applicable
5. Housekeeping
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
23 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 2 of 5
370 - BOOM GEARBOX / REDUCER
Description
Location
Observation
Remark
1. Gearbox oil - Inspect oil level and oil condition
Gearbox #1
Good(
) / Not Good(
)
Gearbox #1
Good(
) / Not Good(
)
Gearbox #1
Good(
) / Not Good(
)
Gearbox #1 : _________degree
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Structure - Inspect mounting bolts tightness and crack
3. Bearing - Inspect abnormal sound
4. Temperature (40 ~ 60 degree)
5. Housekeeping
380 - BOOM MOTOR
Description
1. Sound inspection
Location
Observation
Remark
Boom motor
Good(
) / Not Good(
)
Boom motor
Good(
) / Not Good(
)
Boom emergency motor
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Visual check - Check structure and wire termination
3. Emergency Motor - Check coupling condition - Check limit switch working condition
4. Housekeeping
390 - BOOM WIRE ROPE INSPECTION
Description
Location
Observation
Remark
1. Visual check Wire rope drum
Good(
) / Not Good(
- Broken strands (<18 wires)
Boom tip
Good(
) / Not Good(
)
- Diameter : IMPSA-A : >28.8mm, IMPSA-B : >34.2mm,
A-Frame
Good(
) / Not Good(
)
- Check loosed nut and condition
Length #1
Good(
) / Not Good(
)
Note : Fill up where applicable
Length #2
Good(
) / Not Good(
)
Wire rope
Good(
) / Not Good(
)
All plates
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check broken strands, deformation and kinks
)
ZPMC-A/C : 36mm~33.4mm, ZPMC-B : 32.4mm NOELL/MITSUI : 30mm~2 7.9mm
2. Clips and turnbuckles
3. Check for lubrication - Check rusty
4. Support plate - Check condition 5. Housekeeping
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
24 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 3 of 5
400 - BOOM WIRE ROPE DRUM INSPECTION
Description
Location
Observation
Remark
1. Check wire rope anchor
All drums
Good(
) / Not Good(
)
2. Check bearing any abnormal noise
All drums
Good(
) / Not Good(
)
3. Check groove surface condition
All drums
Good(
) / Not Good(
)
4. Check structure and mounting
All drums
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
5. Housekeeping
410 - BOOM SHEAVE AND BEARING INSPECTION
Description
1. Check groove condition any damaged or rope trace mark
2. Check locking / keeper plate condition
3. Check bearing condition
4. Structure and mounting - Check condition and bolt tightness 5. Housekeeping
Location
Observation
Remark
Boom tip
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
420 - BOOM MOTOR AND GEARBOX COUPLING INSPECTION
Description
1. Check abnormal sound
Location
Observation
Remark
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Check coupling cover Note : Fill up where applicable
3. Check rubber insert condition Note : Fill up where applicable
4. Structure and mounting - Check bolt tightness and condition 5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
25 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST BOOM : Page 4 of 5
430
- BOOM LIMIT SWITCH INSPECTION
Description
Location
Observation
Remark
1. Cable / conduit - Check cable condition, insulation and cable lug
A-Frame
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Limit switch - Check positioning, rusty, functionality and mounting
3. Striker - Check condition 4. Housekeeping
440
- BOOM CAM SWITCH INSPECTION
Description
Location
Observation
Remark
1. Cable termination - Check cable damage and breakage at cable lugs
Boom drum
Good(
) / Not Good(
)
All switches
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
Boom drum
Good(
) / Not Good(
)
Boom drum
Good(
) / Not Good(
)
Boom drum
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Cam switch functionality - Function test
3. Cam switch coupling tightness - Check bolt tightness
4. Check 3-way gear condition Note : Fill up where applicable 5. Driven belt / driven chain - Check belting condition and any crack Note : Fill up where applicable 6. Driven pulley - Check pulley mounting, side guide, wear and crack Note : Fill up where applicable 7. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
26 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 5 of 5
450
- BOOM LATCH INSPECTION
Description
Location
Observation
Remark
1. Servolifter - Check oil condition and any leakage - Check linkage split-pin and conduit condition
A-Frame
Good(
) / Not Good(
)
All limit switches
Good(
) / Not Good(
)
Boom latch
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check rubber bumper Note : Fill up where applicable 2. Limit Switch - Check condition and functionality Note : Fill up where applicable 3. Structure and mounting - Check condition and bolt tightness Note : Fill up where applicable 4. Power pack - Check oil condition and any leakage Note : Fill up where applicable 5. Plunger - Check plunger and spring condition Note : Fill up where applicable 6. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
27 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 1 of 3
460 - EMERGENCY STOP SYSTEM INSPECTION
Description
1. Machinery house - Check functionality and condition Note : Fill up where applicable
2. Trolley
Location
Observation
Remark
Electrical room (inside)
Good(
) / Not Good(
)
PLC panel
Good(
) / Not Good(
)
DC bus shift cub
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
Trolley / hoist emergency station
Good(
) / Not Good(
)
- Check functionality and condition
Trolley house inside
Good(
) / Not Good(
)
Note : Fill up where applicable
Trolley house panel
Good(
) / Not Good(
)
Boom emergency station
Good(
) / Not Good(
)
Boom top outside
Good(
) / Not Good(
)
Boom top inside
Good(
) / Not Good(
)
Boom girder end
Good(
) / Not Good(
)
Checker cabin panel
Good(
) / Not Good(
)
Cabin operator console
Good(
) / Not Good(
)
Boom opeartor cabin
Good(
) / Not Good(
)
Portal landside left
Good(
) / Not Good(
)
Portal landside right
Good(
) / Not Good(
)
Portal seaside left
Good(
) / Not Good(
)
Portal seaside right
Good(
) / Not Good(
)
3. Boom - Check functionality and condition Note : Fill up where applicable
4. Cabin - Check functionality and condition Note : Fill up where applicable 5. Portal - Check functionality and condition Note : Fill up where applicable
6. Others - Check functionality and condition Note : Fill up where applicable
Gantry operation station
Good(
) / Not Good(
)
High voltage cable reel station
Good(
) / Not Good(
)
TLS station
Good(
) / Not Good(
)
Done(
) / Not Done(
)
7. Housekeeping
All location
470 - FLOODLIGHT INSPECTION
Description
1. Boom floodlight
Location
Observation
Remark
Boom tip
Good(
) / Not Good(
- Check functionality and condition
Boom joint
Good(
) / Not Good(
)
- Check wire termination
Boom center cross beam
Good(
) / Not Good(
)
Boom center
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Operator cabin
Good(
) / Not Good(
)
)
2. Trolley floodlight - Check functionality and condition
)
- Check wire termination Note : Fill up where applicable 3. Machinery house
Seaside
Good(
) / Not Good(
- Check functionality and condition
Right hand side
Good(
) / Not Good(
)
- Check wire termination
Left hand side
Good(
) / Not Good(
)
Landside RHS
Good(
) / Not Good(
)
Landside LHS
Good(
) / Not Good(
)
Note : Fill up where applicable
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
28 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY AUXILARY : Page 2 of 3
Description
Location
Observation
Remark
4. Backreach - Check functionality and condition - Check wire termination
Backreach
Good(
) / Not Good(
)
Multi-functional platform
Good(
) / Not Good(
)
Note : Fill up where applicable 5. Portal beam - Check functionality and condition
Right hand side
Good(
) / Not Good(
)
- Check wire termination
Left hand side
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable 6. Housekeeping Housekeeping
480
- OPERATOR CABIN INSPECTION
Description
Location
Observation
Remark
1. Master controller controller / joystick - Check functionality and condition
Right side consol
Good(
) / Not Good(
)
- Check wire termination
Left side consol
Good(
) / Not Good(
)
Wall fan
Good(
) / Not Good(
)
- Check functionality and condition
Cabin lamp
Good(
) / Not Good(
)
- Check wire termination
Power socket
Good(
) / Not Good(
)
- Check power supply functionality
Access gate limit switch
Good(
) / Not Good(
)
Electrical panel
Good(
) / Not Good(
)
- Check functionality and condition
Right side consol
Good(
) / Not Good(
)
- Check wire termination
Left side consol
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
Right side consol
Good(
) / Not Good(
)
Left side consol
Good(
) / Not Good(
)
Siren
Good(
) / Not Good(
)
2. Electrical Electrical system
3. Selector switch and and push button button
4. Indicator Indicator light light - Check functionality and condition - Check wire termination
5. Consol - Check wire termination and condition
6. Foot Foot siren - Check functionality and condition - Check wire termination
Cabin door
Good(
) / Not Good(
)
- Check structure condition
Access gate
Good(
) / Not Good(
)
- Check wind screen/ glass condition
All bushings
Good(
) / Not Good(
)
Handrail
Good(
) / Not Good(
)
Access ladder
Good(
) / Not Good(
)
Support beam
Good(
) / Not Good(
)
Platform
Good(
) / Not Good(
)
Amplifier and speaker
Good(
) / Not Good(
)
Operator seat
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
7. Structure Structure
8. Public Public access (PA) system - Check functionality and condition - Check wire termination
9. Operator seat - Check functionality and condition 10. Housekeeping
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
29 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 3 of 3
490
- AIR-CONDITIONER INSPECTION
Description
Location
Observation
Remark
1. Compressor - Check structure and condition
Control room
Good(
) / Not Good(
)
- Check wire termination and functionality
Operator cabin
Good(
) / Not Good(
)
- Check gas quantity and any leakage
Checker cabin
Good(
) / Not Good(
)
Note : Fill up where applicable 2. Indoor unit - Check structure and condition
Control room
Good(
) / Not Good(
)
- Check wire termination and functionality
Operator cabin
Good(
) / Not Good(
)
Checker cabin
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable 3. Tubing and fitting - Check tube condition and any leakage
4. Mechanical part - Check blower motor mounting condition - Check belting condition - Check cleanliness 5. Housekeeping Housekeeping
500
- SOFTWARE AND PROGRAM MONITORING
Please see attachment (if any)
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
30 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
510 - MAIN HOIST SYSTEM GREASING
Description
Location
Observation
Remark
1. Main hoist system - Pump-in new grease into greasing point Note : Fill up where applicable
2. Housekeeping
520
Headblock sheave
Done(
) / Not Done(
)
Headblock twistlock
Done(
) / Not Done(
)
Backreach-main Backreach-main hoist sheave
Done(
) / Not Done(
)
Trolley platform-mai n hoist sheave
Done(
) / Not Done(
)
Main hoist drum sheave
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
- TROLLEY SYSTEM GREASING
Description
Location
Observation
Remark
1. Trolley Trolley system
- Pump-in new grease into greasing point Note : Fill up where applicable
2. Housekeeping
530
Trolley sheave
Done(
) / Not Done(
)
Trolley floating shaft
Done(
) / Not Done(
)
Trolley plumber block
Done(
) / Not Done(
)
Catenary wheel
Done(
) / Not Done(
)
Catenary sheave
Done(
) / Not Done(
)
Catenary McGill guide roller
Done(
) / Not Done(
)
Backreach- catenary sheave
Done(
) / Not Done(
)
Backreach rope tensioner bearing
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
- BOOM SYSTEM GREASING
Description
Location
Observation
Remark
1. Boom Boom system - Pump-in new grease into greasing point
Boom drum
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable 2. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
31 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 1 of 3
540
- PASSENGER LIFT INSPECTION
Description
Location
Observation
Remark
1. Guide Guide rail All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
Top of cabin
Good(
) / Not Good(
)
All brakes
Good(
) / Not Good(
)
All floors
Good(
) / Not Good(
)
All push buttons
Good(
) / Not Good(
)
Power cable
Good(
) / Not Good(
)
Carrier
Good(
) / Not Good(
)
Inside carrier
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check buffer spring and rail condition - Check mounting condition
2. Gear - Check rack and pinion gear condition
3. Reduction gear box box - Check gearbox conditio n - Check mounting condition
4. Motor - Check casing and mounting condition
5. Brake - Check functionality and brake condition
6. Cabin level - Check setting on each floor level
7. Push button - Check functionality and condition
8. Cable - Check cable insulation and condition - Check protection rubber and mounting condition
9. Carrier structure - Check door and roof door condition - Check ladder condition
10. Intercomm - Check condition and functionality 11. Housekeeping Housekeeping
550 - FIRE FIRE ALARM SYSTEM INSPECTION
Description
Location
Observation
Remark
1. Electrical part - Check AC power LED light up
Machinery house
- Determine Determine standby battery condition ( 25.5 ≤ x ≤ 26.6 26.6 Vdc )
- Zone 1
Good(
) / Not Good(
- Check any alarm LED light up from panel
- Zone 2
Good(
) / Not Good(
)
- Zone 3
Good(
) / Not Good(
)
- Fire, Fault, Off, Extinguisher release, Walk test, External acoustic alarm off, CPU fault, Power supply fault. - Any fault message on the display (Stated the fault message) Note : Fill up where applicable
)
- Zone 4
Good(
) / Not Good(
)
- Main
Good(
) / Not Good(
)
- Charger
Good(
) / Not Good(
)
- Evacuate
Good(
) / Not Good(
)
Good(
) / Not Good(
)
2. Mechanical Part - Visual Check for cylinder pressure gauge reading (±170 bar for 225 bar system) - Examine cylinder valve and hoses for sign of damage, wear or leakage - Inspect all piping & nozzles for any sign damage & leakage Note : Fill up where applicable
Good(
) / Not Good(
)
Good(
) / Not Good(
)
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
32 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 2 of 3
560 - MAINTENANCE HOIST CRANE INSPECTION
Description
Location
Observation
Remark
1. Limit switch and functional test - Hoist up stop
Machinery house
Good(
) / Not Good(
- Hoist up slow down
Machinery house
Good(
) / Not Good(
) )
- Hoist down stop
Machinery house
Good(
) / Not Good(
)
- Trolley forward stop
Machinery house
Good(
) / Not Good(
)
- Trolley forward slow down
Machinery house
Good(
) / Not Good(
)
- Trolley backward stop
Machinery house
Good(
) / Not Good(
)
- Trolley backward slow down
Machinery house
Good(
) / Not Good(
)
- Gantry right stop
Machinery house
Good(
) / Not Good(
)
- Gantry right slow down
Machinery house
Good(
) / Not Good(
)
- Gantry left stop
Machinery house
Good(
) / Not Good(
)
- Gantry left slow down
Machinery house
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
Rubber buffer
Good(
) / Not Good(
)
Hook block
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
Electrical box
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Control console - Check functionality and condition - Check structure
3. Structure - Check structure condition - Check hook and latch condition
4. Wire rope and turn buckle - Check loosed nut and wire rope condition - Check any rusty
5. Electrical part - Check wire termination and contactor condition 6. Housekeeping
570
- AIR COMPRESSOR INSPECTION
Description
Location
Observation
Remark
1. Compressor - Check oil level sufficient, air filter, V-belt, pressure gauge,
Machinery house
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
safety valve, piping and mounting condition - Check any abnormal sound or vibration
2. Pressure Switch - Check pressure setting Note : Cut in: 9.9 kg/cm2 & Cut out: 8.0 kg/cm2 - Adjusting screw locknut and check wire termination
3. Motor - Check mounting and any abnormal sound
4. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
33 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST AUXILARY : Page 3 of 3
580 - QC CHECKER CABIN INSPECTION
Description
Location
Observation
Remark
1. Socket & power supply - Check mounting and condition
2. Check lighting condition and functionality
All location
Good(
) / Not Good(
)
Cabin ceiling
Good(
) / Not Good(
)
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
3. Intercomm - Check condition and functionality
4. Structure - Check mounting and condition - Check door and glass
5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
34 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM: Page 1 of 1
590
- BOOM FORESTAY INSPECTION
Description
Location
Observation
Remark
1. Bushing - Check abnormal sound and vibration
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All supports
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Structure and mounting - Check condition and mounting
3. Rest support - Check forestay rest support condition
4. Boom buffer - Check condition and mounting
5. Housekeeping
600
- BOOM SHEAVE INSPECTION
Description
Location
Observation
Remark
1. Check bearing condition
All sheaves
Good(
) / Not Good(
)
2. Check grove condition
All sheaves
Good(
) / Not Good(
)
All sheaves
Good(
) / Not Good(
)
All sheaves
Done(
) / Not Done(
)
3. Structure - Check mounting and condition
4. Housekeeping
610
- BOOM CABIN INSPECTION
Description
Location
Observation
Remark
1. Indicator bulb - Check condition and functionality
2. Check lighting condition and functionality
All indicators bulbs
Good(
) / Not Good(
)
Cabin ceiling
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Done(
) / Not Done(
)
3. Structure - Check mounting and condition - Check door and glass
4. Intercomm - Check condition and functionality
5. Housekeeping
General Remark :
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
35 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
620
- GANTRY SYSTEM GREASING
Description
Location
Observation
Remark
1. Gantry system - Pump-in new grease into greasing point
2. Housekeeping
630
All boggies
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
- BOOM SYSTEM GREASING
Description
Location
Observation
Remark
1. Boom system - Pump-in new grease into greasing point
2. Housekeeping
All boom sheaves
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
640 - MAIN HOIST WIRE ROPE LUBRICATION
Description
Location
Observation
Remark
1. Main hoist wire rope - Check condition and lubricate wire rope
2. Housekeeping
All main hoist wire ropes
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
650 - TROLLEY WIRE ROPE LUBRICATION
Description
Location
Observation
Remark
1. Trolley wire rope - Check condition and lubricate wire rope
All trolley wire ropes
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable 2. Housekeeping
660
- BOOM WIRE ROPE LUBRICATION
Description
Location
Observation
Remark
1. Boom wire rope - Check condition and lubricate wire rope
2. Housekeeping
670
All boom wire ropes
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
- CATERNARY WIRE ROPE LUBRICATION
Description
Location
Observation
Remark
1. Catenary wire rope - Check condition and lubricate wire rope
All caternary wire ropes
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable 2. Housekeeping
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
36 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 1 of 1
680 - MAIN CABLE REEL INSPECTION Description
Location
Observation
Remark
1. Motor - Check mounting and condition
Main cable reel motor
Good(
) / Not Good(
)
Main power cable
Good(
) / Not Good(
)
All mounting
Good(
) / Not Good(
)
Good(
) / Not Good(
)
2. Main cable - Check cable condition
3. Structure - Check mounting and condition
4. Slip ring - Check slip rings condition
5. Gearbox - Check gearbox oil condition
Good(
) / Not Good(
)
- Check mounting and condition
Good(
) / Not Good(
)
- Check any abnormal sound
Good(
) / Not Good(
)
Done(
) / Not Done(
)
6. Housekeeping
General Remark :
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
37 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
690
- BOOM BACKSTAY GREASING
Description
Location
Observation
Remark
1. Boom backstay - Pump-in new grease into greasing point
All greasing points
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
2. Housekeeping
700
- KBT COUPLING GREASING
Description
Location
Observation
Remark
1. KBT coupling - Pump-in new grease into greasing point
Done(
) / Not Done(
)
Done(
) / Not Done(
)
Note : Fill up where applicable Please see attachment (No. :
2. Housekeeping
General Remark :
)
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
38 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AC/DC MEGGER : Page 1 of 1
710 - MAIN HOIST AC & DC MOTOR INSULATION READING
Note : Fill up where applicable Please see attachment (No. :
)
720 - TROLLEY AC & DC MOTOR INSULATION READING
Note : Fill up where applicable Please see attachment (No. :
)
730 - BOOM AC & DC MOTOR INSULATION READING
Note : Fill up where applicable Please see attachment (No. :
740
)
- GANTRY AC & DC MOTOR INSULATION READING
Note : Fill up where applicable Please see attachment (No. :
General Remark :
)
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
1 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST MONTH / YEAR
:
CRANE NUMBER
:
JOB NUMBER
:
W.O. NUMBER
:
DATE /TIME START : DATE/TIME END
:
HOUR METER READING : CRANE
:
MAIN HOIST
:
LAND SIDE (FOR DUAL HOIST CRANE)
SEA SIDE (FOR DUAL HOIST CRANE)
TROLLEY
:
GANTRY
:
BOOM
:
PM CHECKLIST TYPE : Please tick ( X ) where applicable :
MONTHLY PM
:
Page 1 to page 30
(
)
QUARTERLY PM
:
Page 1, page 31 to page 36
(
)
SEMI-ANNUALLY PM : PM :
Page 1, page 37 to page 38
(
)
ANNUALLY PM
Page 1 to page 38
(
)
SYSTEM :
:
PREPARED BY :
SIGNATURE :
MAIN HOIST SYSTEM Date :
TROLLEY SYSTEM Date :
GANTRY SYSTEM Date :
BOOM SYSTEM Date :
AUXIALLARY SYSTEM Date :
GREASING Date :
VERIFIED BY :
SIGNATURE :
Date :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
2 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 1 of 8
10
- MAIN HOIST BRAKE
10.1 - SERVICE BRAKE
Description
Location
Observation
Remark
Brake #1 (Height : _________ mm)
Good(
) / Not Good(
)
- Inspect stroke indicator setting and manual release
Brake #2 (Height : _________ mm)
Good(
) / Not Good(
)
Note : Burbenzer brake 25mm
Brake #3 (Height : _________ mm)
Good(
) / Not Good(
)
Brake #4 (Height : _________ mm)
Good(
) / Not Good(
)
1. Reserve stroke stroke height
ZPMC Brake 10mm
. ra ra ng orqu orque e
Brak Brake e #1 (Tor (Torqu que e : ________________ Nm) Nm)
Good( ood(
) / Not Not Good( ood(
)
- Inspect setting and mechanical component
Brak Brake e #2 (Tor (Torqu que e : ________________ Nm) Nm)
Good( ood(
) / Not Not Good( ood(
)
Note :
Brak Brake e #3 (Tor (Torqu que e : ________________ Nm) Nm)
Good( ood(
) / Not Not Good( ood(
)
Brak Brake e #4 (Tor (Torqu que e : ________________ Nm) Nm)
Good( ood(
) / Not Not Good( ood(
)
All brakes
Good(
) / Not Good(
)
ZPMC-C : 19kNm
3. Air gap - Check any rubbing
Brake #1 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
- Inspect pad and disc
Brake #1 LHS : ______mm
Good(
) / Not Good(
)
- Check and clean disc surface
Brake #2 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Note : Fill up where applicable
Brake #2 LHS : ______mm
Good(
) / Not Good(
)
Brake #3 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #3 LHS : ______mm
Good(
) / Not Good(
)
Brake #4 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #4 LHS : ______mm
Good(
) / Not Good(
)
4. Brake pad and disc
ZPMC-C (Pad : > 3 mm, Disc wear more than 20%)
Brake #1
Good(
) / Not Good(
)
- Check Check one way bearing and adjusting nut condition
Brake #2
Good(
) / Not Good(
)
- Check gap AMC to catched plate
Brake #3
Good(
) / Not Good(
)
- Check adjustment AWC pin drive
Brake #4
Good(
) / Not Good(
)
Brake #1
Good(
) / Not Good(
)
Brake #2
Good(
) / Not Good(
)
Brake #3
Good(
) / Not Good(
)
Brake #4
Good(
) / Not Good(
)
All servolifters
Good(
) / Not Good(
)
Good(
) / Not Good(
)
5. Check AWC condition
6. Check wedge and shackle kit Note : Applicable for Burbenzer brake only
7. Servolifter / Thruster - Inspect oil, electrical and mechanical part
8. Structure Structure - Check pivot pin, linkage and mounting
9. Limit Switch - Check setting and functionality Note : Fill up where applicable 10. Housekeeping
General Remark :
a. Brake manual release
Good(
) / Not Good(
)
b. Brake release
Good(
) / Not Good(
)
c. Brake pad wear
Good(
) / Not Good(
)
Done(
) / Not Done(
)
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
3 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 2 of 8
10.2 - EMERGENCY BRAKE ( MAIN & AUX)
Description
1. Hydraulic Hydraulic Tank
Location
Observation
Remark
Mechinery House
- Check oil condition
Good(
) / Not Good(
)
- Check oil level
Good(
) / Not Good(
)
- Check working pressure (150 -180 bar)
Good(
) / Not Good(
)
- Check tank condition
Good(
) / Not Good(
)
2. Hydraulic cylinder cylinder and block - Check hoses leakage
Good(
) / Not Good(
)
- Check solenoid coil & dim plugs
Good(
) / Not Good(
)
- Check valve leakage & functions functio ns
Good(
) / Not Good(
)
Brake #1
Good(
) / Not Good(
)
Brake #2
Good(
) / Not Good(
)
Brake #3
Good(
) / Not Good(
)
Brake #4
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
3. Proximity sensor - Check setting and functionality Note : Fill up where applicable
4. Motor & Electrical Components - Check electrical termination - Measure Motor demands
Phase 1: _______(A) Phase 2: _______(A) Phase 3: _______(A)
5. Brake pad and disc - Inspect Inspect pad and disc (Pad : ≤ 8 mm, Disc : ≥ 28 mm)
Disc Plate#1 RHS : ______mm
Good(
) / Not Good(
)
- Check and clean disc surface
Disc Plate#1 LHS : ______mm
Good(
) / Not Good(
)
Note : Fill up where applicable
Disc Drum#1 RHS : ______mm
Good(
) / Not Good(
)
Disc Drum #1 LHS : ______mm
Good(
) / Not Good(
)
Disc Plate#2 RHS : ______mm
Good(
) / Not Good(
)
Disc Plate #2 LHS : ______mm
Good(
) / Not Good(
)
Disc Drum#2 RHS : ______mm
Good(
) / Not Good(
)
Disc Drum #2 LHS : ______mm
Good(
) / Not Good(
)
Done(
) / Not Done(
)
6. Housekeeping
General Remark :
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
4 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 3 of 8
20 - MAIN HOIST GEARBOX / REDUCER
Description
Location
Observation
Remark
1. Gearbox oil - Inspect oil level and oil condition Note : Fill up where applicable
Gearbox #1 (Main)
Good(
) / Not Good(
)
Gearbox #2 (Aux)
Good(
) / Not Good(
)
2. Structure - Inspect mounting bolts tightness and crack Note : Fill up where applicable
Gearbox #1 (Main)
Good(
) / Not Good(
)
Gearbox #2 (Aux)
Good(
) / Not Good(
)
3. Bearing - Inspect abnormal sound Note : Fill up where applicable
4. Temperature (40 ~ 60 degree) Note : Fill up where applicable
5. Housekeeping
Gearbox #1 (Main)
Good(
) / Not Good(
)
Gearbox #2 (Aux)
Good(
) / Not Good(
)
Gearbox #1 : _________degree
Good(
) / Not Good(
)
Gearbox #2 : _________degree
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
30 - MAIN HOIST DRIVE & BLOWER MOTOR
Description
1. Sound inspection Note : Fill up where applicable
2. Check heater
Location
Observation
Remark
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
Motor #3
Good(
) / Not Good(
)
Motor #4
Good(
) / Not Good(
)
Motor #1 ( _____ Ohm)
Good(
) / Not Good(
)
Motor #2 ( _____ Ohm)
Good(
) / Not Good(
)
Motor #3 ( _____ Ohm)
Good(
) / Not Good(
)
Motor #4 ( _____ Ohm)
Good(
) / Not Good(
)
3. Visual check - Check coupling motor & gear box (Bush Coupling)
Motor #1
Good(
) / Not Good(
)
- Check terminations
Motor #2
Good(
) / Not Good(
)
- Check mounting bolts and frame
Motor #3
Good(
) / Not Good(
)
Motor #4
Good(
) / Not Good(
)
Note : Fill up where applicable
Motor #1 ( 1._____ A 2. _____ A 3. _____ A)
Good(
) / Not Good(
)
- Check rotation
Motor #2 ( 1._____ A 2. _____ A 3. _____ A)
Good(
) / Not Good(
)
- Check running cond
Motor #3 ( 1._____ A 2. _____ A 3. _____ A)
Good(
) / Not Good(
)
- Measure motor demands
Motor #4 ( 1._____ A 2. _____ A 3. _____ A)
Good(
) / Not Good(
)
4. Check blower motor cond.
- Check coupling condition
5. Emergency Motor - Check coupling condition & chain link
Motor #1
Good(
) / Not Good(
)
- Check limit switch working condition
Motor #2
Good(
) / Not Good(
)
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
Motor #3
Good(
) / Not Good(
)
Motor #4
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
6. Air Filter - Check clealiness
7. Housekeeping
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
5 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 4 of 8
40 - MAIN HOIST WIRE ROPE INSPECTION
Description
Location
Observation
Remark
1. Visual check - Check broken strands, deformation and kinks
Drum
Good(
) / Not Good(
- Diameter (ZPMC-C : 32.00mm~29.76mm)
Backreach
Good(
) / Not Good(
)
- Broken strands (<18 wires)
Trolley platform
Good(
) / Not Good(
)
Note : Fill up where applicable
Headblock
)
Good(
) / Not Good(
)
Main Girder Area (5 mtr before Joint)
Good(
) / Not Good(
)
Boom Girder Area (5 mtr after Joint)
Good(
) / Not Good(
)
Length #1
Good(
) / Not Good(
)
- Check loosed nut and condition
Length #2
Good(
) / Not Good(
)
- Check installation
Length #3
Good(
) / Not Good(
)
Length #4
Good(
) / Not Good(
)
Length #1
Good(
) / Not Good(
)
DRIED/RUSTED/OILY
Length #2
Good(
) / Not Good(
)
DRIED/RUSTED/OILY
Length #3
Good(
) / Not Good(
)
DRIED/RUSTED/OILY
Length #4
Good(
) / Not Good(
)
DRIED/RUSTED/OILY
All rollers and plates
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Clips and Clamp
3. Check for lubrication
4. Support roller and plate - Check condition 5. Housekeeping
50 - MAIN HOIST WIRE ROPE DRUM INSPECTION
Description
Location
Observation
Remark
1. Check wire rope anchor
All drums
Good(
) / Not Good(
)
2. Check bearing any abnormal noise
All drums
Good(
) / Not Good(
)
3. Check groove surface condition
All drums
Good(
) / Not Good(
)
4. Check structure and mounting
All drums
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
6 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 5 of 8
60 - MAIN HOIST SHEAVE AND BEARING INSPECTION Description
1. Check groove condition any damaged or rope trace mark Note : Fill up where applicable
2. Check locking / keeper plate condition Note : Fill up where applicable
Location
Observation
Remark
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Headblock
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Backreach
Tight(
) / Loose(
)
Trolley platform
Tight(
) / Loose(
)
Headblock
Tight(
) / Loose(
)
Boom tip
Tight(
) / Loose(
)
Backreach
Good(
) / Not Good(
)
- No abnormal noise
Trolley platform
Good(
) / Not Good(
)
- Sheave seat on the shaft firmly
Headblock
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
3. Check bearing condition
4. Housekeeping
70 - MAIN HOIST MOTOR AND GEARBOX COUPLING INSPECTION Description
1. Check abnormal sound
Location
Observation
All couplings
Normal(
All couplings
Good(
Remark
) / Abnormal(
)
2. Check coupling cover Note : Fill up where applicable
) / Not Good(
)
3. Check rubber insert condition Note : Fill up where applicable
All couplings
Unwear(
All couplings
Tight (
) / Wear (
)
4. Structure - Check bolt tightness and condition
5. Housekeeping
General Remark :
All location
Done(
) / Loose(
) / Not Done(
)
)
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
7 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 6 of 8
80 - MAIN HOIST CAM SWITCH INSPECTION
Description
Location
Observation
Remark
1. Cable termination - Check cable damage and breakage at cable lugs
Main hoist drum
Good(
) / Not Good(
)
All switches
Good(
) / Not Good(
)
2. Cam switch functionality - Function test
3. Cam switch coupling tightness - Check bolt tightness
All couplings
Tight (
) / Loose (
)
Note : Fill up where applicable
4. Check cam switch set
Main hoist drum
Good(
) / Not Good(
)
- Check mounted bolt tightness
5. Cam Switch Gear Reducer - Check oil/lubricant condition
Main hoist drum
- Check oil/lubricant level - Check for noisy sound
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Normal(
6. Housekeeping
All location
) / Abnormal(
Done(
)
) / Not Done(
)
90 - MAIN HOIST LIMIT SWITCH (STOP UP/OVER TRAVEL) INSPECTION
Description
Location
Observation
Remark
1. Cable / conduit - Check cable condition, insulation and cable lug
Trolley platform / trolley house
Good(
) / Not Good(
)
Trolley platform / trolley house
2. Limit switch Good(
) / Not Good(
)
- Check rusty
Good(
) / Not Good(
)
- Check functionality
Good(
) / Not Good(
)
- Check mounting
Good(
) / Not Good(
)
Spreader cable / headblock
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check positioning
3. Striker - Check condition Note : Fill up where applicable 4. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
8 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 7 of 8
100
- MAIN HOIST ENCODER INSPECTION
Description
Location
Observation
Remark
1. Coupling - Check mounting
Main hoist motor and drum
Tight(
) / Loose (
)
- Check rusty
Not rusted(
) / Rusted(
- Check alignment
Good(
) / Not Good(
) )
Main hoist drum
Good(
) / Not Good(
)
Main hoist drum
Good(
) / Not Good(
)
4. Functionality
Main hoist drum
Done(
) / Not Done(
)
5. Housekeeping
All location
Done(
) / Not Done(
)
2. Coupling Reducer - Check condition
3. Electrical Termination - Check cable connection Note : Fill up where applicable
110 - MAIN HOIST OVER SPEED DETECTOR INSPECTION
Description
Location
Observation
Remark
1. Cable termination - Check cable damage and breakage at cable lugs
Main hoist drum
Good(
) / Not Good(
)
2. Coupling tightness - Check bolt tightness
All couplings
3. Housekeeping
120
All location
Tight (
Done(
) / Loose (
)
) / Not Done(
)
- SPREADER CABLE REEL INSPECTION
Description
1. Spreader drum / reel
Location
Observation
Remark
Trolley platform
- Check drum condition
Drum Reel # 1
Good(
) / Not Good(
)
- Check cable condition & arrangement
Drum Reel # 2
Good(
) / Not Good(
)
Drum Reel # 1
Good(
) / Not Good(
)
2. Driven belt / driven chain (cam switch) - Check belting condition and any crack Note : Fill up where applicable
Drum Reel # 2
3. Magnetic Clutch - Check bearings condition
- Check for noisy sound
- Check air gap - Measure current demand
Motor# 1
Unwear(
) / Wear(
)
Motor# 2
Unwear(
) / Wear(
)
Motor# 3
Unwear(
) / Wear(
)
Motor# 4
Unwear(
) / Wear(
)
Motor# 1
Normal(
) / Abnormal(
)
Motor# 2
Normal(
) / Abnormal(
)
Motor# 3
Normal(
) / Abnormal(
)
Motor# 4
Normal(
) / Abnormal(
Motor# 1 ( _____ A; _____mm )
Good(
) / Not Good(
)
)
Motor# 2 ( _____ A; _____mm )
Good(
) / Not Good(
)
Motor# 3 ( _____ A; _____mm )
Good(
) / Not Good(
)
Motor# 4 ( _____ A; _____mm )
Good(
) / Not Good(
)
4. Electrical - Check cable connection and slip ring carbon brushes - Check short length cable and junction box
Trolley platform
Good(
) / Not Good(
)
Headblock
Good(
) / Not Good(
)
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
9 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 8 of 8
Description
Location
Observation
Remark
5. Limit switch - Check limit switch condition
Trolley platform
Good(
) / Not Good(
)
Headblock
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
6. Absorber - Check condition 7. Housekeeping
130 - SPREADER HEADBLOCK
Description
Location
Observation
Remark
1. Twistlock - Check gap, lock pin and condition
All twistlocks
Unwear(
) / Wear(
)
No Crack(
) / Crack (
)
2. Switches - Check headblock connected cond.
Headblock lock/unlock lever
Good(
) / Not Good(
)
- Check headblock anchor sensor cond.
Headblock lock/unlock lever
Good(
) / Not Good(
)
3. Structure & Hydraulic System - Check condition, ladder, hand rail and grating
Good(
) / Not Good(
)
- Check hyd. Tank oil level
Good(
) / Not Good(
)
- Check hyd. Hoses
All location
- Check hyd. Valves - Check hyd. Tank rubber mountings
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Unwear(
- Check hyd. Tank rubber bolts
Tight(
) / Wear( ) / Loose(
) )
140 - TRIM, LIST AND SKEW (TLS) SYSTEM INSPECTION
Description
Location
Observation
Remark
1. Power pack - Check oil level, condition and cleanliness - Check working pressure (160±10 psi)
TLS platform
Good(
) / Not Good(
Pressure : _________ psi
Good(
) / Not Good(
No leak(
- Check hose, valve and piping
) )
) / Leak(
)
No Leak(
) / Leak(
)
Unwear(
) / Wear(
)
2. Hydraulic cylinder - Check oil leak
TLS platform
- Check guide roller
Smoothed(
- Check piston surface condition
) / Scratched(
)
3. Positioner sensor - Check mounting
All cylinders
Tight( No crack(
- Check crack
) / Loose( ) / Crack(
) )
4. Motor and pump - Check abnormal sound
All motors and pumps
- Check overheating
Normal(
) / Abnormal(
)
Normal(
) / Overheat(
)
- Check cover
In place(
) / Missing(
)
- Check electrical connection
Good(
) / Not Good(
)
All control boxes
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
5. TLS control panel - Check wire termination, conduit and DC supply - Check door and lock condition 6. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
10 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 1 of 8
150
- TROLLEY BRAKE INSPECTION Description
1. Reserve stroke height
Location
Observation
Remark
Brake #1 (Height : _________ mm)
Good(
) / Not Good(
)
Brake #1 (Torque : ________________ Nm)
Good(
) / Not Good(
)
All brakes
Good(
) / Not Good(
)
Brake #1 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #1 LHS : ______mm
Good(
) / Not Good(
)
Brake #1
Good(
) / Not Good(
)
Brake #1
Good(
) / Not Good(
)
All servolifters
Good(
) / Not Good(
)
Good(
) / Not Good(
)
- Inspect stroke indicator setting and manual release Note : Burbenzer brake 25mm ZPMC Brake 10mm
. ra ng orque - Inspect setting and mechanical component Note : IMPSA-A : ≥ 977Nm, NOELL /MITSUI/ZPMC-A : ≥ 1890Nm IMPSA-B : ≥ 977Nm , ZPMC-B : ≥ 5175 Nm, ZPMC-C : 5500Nm
3. Air gap - Check any rubbing
4. Brake pad and disc - Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm)
ZPMC-C: Disk wear >20% from 30mm, Pad >3mm ZPMC(Pad : ≥ 3 mm, Disc : ≤ 1.0mm wear on each side)
- Check and clean disc surface Note : Fill up where applicable
5. Check AWC condition - Check one way bearing and adjusting nut condition Note : Fill up where applicable
6. Check wedge and shackle kit Note : Applicable for Burbenzer brake only
7. Servolifter / Thruster - Inspect oil, electrical and mechanical part
8. Structure - Check pivot pin, linkage and mounting
9. Limit Switch - Check setting and functionality Note : Fill up where applicable
10. Housekeeping
General Remark :
a. Brake manual release
Good(
) / Not Good(
)
b. Brake release
Good(
) / Not Good(
)
c. Brake pad wear
Good(
) / Not Good(
)
Done(
) / Not Done(
)
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
11 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 2 of 8
160 - TROLLEY GEARBOX INSPECTION Description
1. Gearbox oil
Location
Observation
Remark
Gearbox #1
Good(
) / Not Good(
)
Gearbox #1
Good(
) / Not Good(
)
Gearbox #1
Good(
) / Not Good(
)
Gearbox #1 : _________degree
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Inspect oil level and oil condition Note : Fill up where applicable
2. Structure - Inspect mounting bolts tightness and crack Note : Fill up where applicable
3. Bearing - Inspect abnormal sound Note : Fill up where applicable
4. Temperature (40 ~ 60 degree) Note : Fill up where applicable
5. Housekeeping
170
- TROLLEY MOTOR INSPECTION Description
1. Sound inspection
Location
Observation
Remark
Motor #1
Good(
) / Not Good(
)
Motor #1
Good(
) / Not Good(
)
Note : Fill up where applicable
2. Emergency motor - Check coupling condition - Check limit switch working condition
3. Housekeeping
All location
Done(
) / Not Done(
)
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
12 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 3 of 8
180
- TROLLEY WIRE ROPE INSPECTION
Description
Location
Observation
Remark
1. Visual check - Check broken strands, deformation and kinks
Drum
Good(
) / Not Good(
- Diameter ( 24.18mm to 26.00mm)
Backreach
Good(
) / Not Good(
)
- Broken strands (<18 wires)
Trolley platform
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Length #1
Good(
) / Not Good(
)
Length #2
Good(
) / Not Good(
)
Note : Fill up where applicable
2. Clips and turnbuckles - Check loosed nut and condition 3. Check for lubrication - Check rusty
)
Length #1
Good(
) / Not Good(
)
Length #2
Good(
) / Not Good(
)
All rollers and plates
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
4. Support roller and plate - Check condition 5. Housekeeping
190 - TROLLEY WIRE ROPE DRUM INSPECTION
Description
Location
Observation
Remark
1. Check wire rope anchor
All drums
Good(
) / Not Good(
)
2. Check bearing any abnormal noise
All drums
Good(
) / Not Good(
)
3. Check groove surface condition
All drums
Good(
) / Not Good(
)
4. Check structure and mounting
All drums
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
13 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 4 of 8
200 - TROLLEY SHEAVE AND BEARING INSPECTION
Description
1. Check groove condition any damaged or rope trace mark Note : Fill up where applicable
2. Check locking / keeper plate condition Note : Fill up where applicable
3. Check bearing condition Note : Fill up where applicable
4. Housekeeping
Location
Observation
Remark
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
210 - TROLLEY MOTOR AND GEARBOX COUPLING INSPECTION
Description
1. Check abnormal sound
Location
Observation
Remark
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
2. Check coupling cover Note : Fill up where applicable
3. Check rubber insert condition Note : Fill up where applicable
4. Structure - Check bolt tightness and condition
220
- TROLLEY WHEEL INSPECTION
Description
1. Wheel - Check wheel bearing condition and abnormal sound
2. Structure - Check wheel flange cracks or damages and condition
3. Guide roller - Check bearing and guide roller condition
4. Housekeeping
Location
Observation
Remark
Wheel #1
Good(
) / Not Good(
)
Wheel #2
Good(
) / Not Good(
)
Wheel #3
Good(
) / Not Good(
)
Wheel #4
Good(
) / Not Good(
)
Wheel #1
Good(
) / Not Good(
)
Wheel #2
Good(
) / Not Good(
)
Wheel #3
Good(
) / Not Good(
)
Wheel #4
Good(
) / Not Good(
)
Wheel #1
Good(
) / Not Good(
)
Wheel #2
Good(
) / Not Good(
)
Wheel #3
Good(
) / Not Good(
)
Wheel #4
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
Document No.
SUPPORTING DOCUMENT
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
14 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST TROLLEY : Page 5 of 8
230
- TROLLEY RAIL INSPECTION
Description
Location
Observation
Remark
1. Trolley rail structure
- Check greasy or oily
All
Good(
) / Not Good(
- Check rail clip, bolt and nut
All
Good(
) / Not Good(
)
- Check welded part cracked or chipped
All
Good(
) / Not Good(
)
- Check side plate bolt tightness
Boom joint
Good(
) / Not Good(
)
- Check trolley rail gap
Boom joint
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Housekeeping
)
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
15 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 6 of 8
240 - TROLLEY LIMIT SWITCH INSPECTION
Description
Location
Observation
Remark
1. Cable and conduit Good(
) / Not Good(
)
All limit switches
Good(
) / Not Good(
)
All flag sensors
Good(
) / Not Good(
)
- Check insulation, termination and condition
2. Limit switch - Check condtion, mounting and functionality 3. Flag sensor - Check condtion, mounting and functionality
4. Slowdown magnet - Check condtion, mounting and functionality 5. Housekeeping
250
Boom tip
Good(
) / Not Good(
)
Backreach
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- TROLLEY ENCODER INSPECTION
Description
Location
Observation
Remark
1. Coupling - Check mounting, rusty, alignment and sprider wear
Trolley motor
Good(
) / Not Good(
)
Trolley motor
Good(
) / Not Good(
)
Trolley LS LHS
Good(
) / Not Good(
)
Trolley motor
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
2. Electrical - Check cable connection
3. Structure - Check mounting, wheel and bearing condition Note : Fill up where applicable
4. Encoder sensor - Check sensor surface and condition
3. Housekeeping
260
- TROLLEY CATENARY INSPECTION
Description
Location
Observation
Remark
1. Wheel bearings - Check abnormal noise
All location
Good(
) / Not Good(
)
2. Trolley wheel - Check any crack or damage on wheel flange
All wheels
Good(
) / Not Good(
)
- Check wheel bracket bolts tighten
All wheel brackets
Good(
) / Not Good(
)
- Check wheel cover bolt tightness
All bolts
Good(
) / Not Good(
)
Note : Fill up where applicable
3. Sheave and bearing - Check groove condition
1. Boom tip LHS and RHS
Good(
) / Not Good(
)
- Check sheave bearing abnormal sound and condition
2. Catenary LS LHS and RHS
Good(
) / Not Good(
)
- Check locking /keeper plate bolts and nuts condition
3. Catenary SS LHS and RHS
Good(
) / Not Good(
)
Note : Fill up where applicable
4. Backreach LHS and RHS
SUPPORTING DOCUMENT
Good(
) / Not Good(
)
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
16 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 7 of 8
Description
Location
Observation
Remark
4. Catenary wire rope - Visual check for wear, deformation and kinks Note : Fill up where applicable
1. Drive rope LHS and RHS
Good(
) / Not Good(
)
2. Tie rope LHS and RHS
Good(
) / Not Good(
)
Good(
) / Not Good(
)
1. Catenary Landside
Good(
) / Not Good(
)
2. Catenary Seaside
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
5. Clip and turnbuckle - Check clips and turnbuckles condition
All location
Note : Fill up where applicable
6. Structure - Check catenary structure condition Note : Fill up where applicable
7. Guide roller - Check guide roller tighness and condition
8. Support roller - Check support roller, bearing and shaft condition
9. Housekeeping
270 - TROLLEY WIRE ROPE TENSIONER INSPECTION
Description
Location
Observation
Remark
1. Cylinder - Check abnormal sound and cylinder condition - Check hose and any leakage
All cylinders
Good(
) / Not Good(
)
Note : Fill up where applicable 2. Cross joint - Check vibration and any abnormal sound
All location
Good(
) / Not Good(
)
- Check bearing and shaft condition
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All limit switches
Good(
) / Not Good(
)
All limit switches
Good(
) / Not Good(
)
All power units
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
3. Sheave - Check bolt tighness, sheave and bearing condition
4. Limit switch - Check limit switch condition and functionality
5. Hydraulic power pack - Check tank, hose and fitting condition - Check any leakage and oil level
6. Power unit for motor pump - Check abnormal sound, termination and condition 7. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
17 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 8 of 8
280
- FESTOON SYSTEM INSPECTION
Description
Location
Observation
Remark
1. Festoon rail - Check deformation, dents and leveling condition
Along rails
Good(
) / Not Good(
)
All cables
Good(
) / Not Good(
)
All shackles and elastic cords
Good(
) / Not Good(
)
All bumpers
Good(
) / Not Good(
)
All rollers
Good(
) / Not Good(
)
2. Festoon cable - Check cable and cable clamp mouting condition
3. Sling shackle and elastic cord - Check any cut, broken and wear condition - Check sling shackle missing and condition
4. Festoon bumper - Check mounting and bumber condition
5. Side roller, runner wheel and anti-lift roller - Check roller condition and abnormal sound - Check mounting condition
6. Belting system Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
Motor #3
Good(
) / Not Good(
)
- Check abnormal sound and mounting condition
Motor #1
Good(
) / Not Good(
)
- Check bolt tightness and motor cover condition
Motor #2
Good(
) / Not Good(
)
Motor #3
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
All carrier
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check belting, pulley and bearing condition Note : Fill up where applicable
7. Motor (Brand : VAHLE or WAMPFLER)
Note : Fill up where applicable
8. Trolley festoon box - Check cable termination and slot connection condition - Check door seal condition 9. Festoon carrier - Check carrier condition
10. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
18 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 1 of 4
290
- GANTRY BRAKE INSPECTION
Description
Location
Observation
Remark
1. Gantry brake - Check wire termination - Check friction disc, stationary disc and coil assembly
All brakes
Good(
) / Not Good(
)
- Check mounting cover and silicon seal condition Note : Fill up where applicable
2. Reserve stroke height (10 mm) - Inspect stroke indicator setting and manual release Note : Fill up where applicable
Landside H eight : #1 : ______ mm
#5 : ______ mm)
Good(
) / Not Good(
)
H eight : #2 : ______ mm
#6 : ______ mm)
Good(
) / Not Good(
)
H eight : #3 : ______ mm
#7 : ______ mm)
Good(
) / Not Good(
)
H eight : #4 : ______ mm
#8 : ______ mm)
Good(
) / Not Good(
)
H eight : #1 : ______ mm
#5 : ______ mm)
Good(
) / Not Good(
)
H eight : #2 : ______ mm
#6 : ______ mm)
Good(
) / Not Good(
)
H eight : #3 : ______ mm
#7 : ______ mm)
Good(
) / Not Good(
)
H eight : #4 : ______ mm
#8 : ______ mm)
Good(
) / Not Good(
)
Seaside
. ra ng orque
Landside
- Inspect setting and mechanical component
Torque : #1 : ______ Nm
#5 : ______ Nm)
Good(
) / Not Good(
)
Note : Fill up where applicable
Torque : #2 : ______ Nm
#6 : ______ Nm)
Good(
) / Not Good(
)
Torque : #3 : ______ Nm
#7 : ______ Nm)
Good(
) / Not Good(
)
Torque : #4 : ______ Nm
#8 : ______ Nm)
Good(
) / Not Good(
)
Torque : #1 : ______ Nm
#5 : ______ Nm)
Good(
) / Not Good(
)
Torque : #2 : ______ Nm
#6 : ______ Nm)
Good(
) / Not Good(
)
Torque : #3 : ______ Nm
#7 : ______ Nm)
Good(
) / Not Good(
)
Torque : #4 : ______ Nm
#8 : ______ Nm)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
IMPSA-B : > 207Nm, ZPMC-B : >320Nm, ZPMC-C : 350Nm
Seaside
4. Air gap - Check any rubbing
All brakes
Note : Fill up where applicable
5. Brake pad and disc (Landside) - Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm)
- Check and clean disc surface
Brake #1 RHS : _____mm, LHS _____mm Disc : _____mm
Note : Fill up where applicable Brake #2 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #3 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #4 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #5 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #6 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #7 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #8 RHS : _____mm, LHS _____mm
Disc : _____mm
SUPPORTING DOCUMENT
Good(
) / Not Good(
)
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
19 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 2 of 4
Description
Location
Observation
Remark
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
All brakes
Good(
) / Not Good(
)
All servolifters
Good(
) / Not Good(
)
- Check pivot pin, linkage, mounting and cover
All brakes
Good(
) / Not Good(
)
- Check limit switch setting and functionality
All brakes
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
6. Brake pad and disc (Seaside) - Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm)
Brake #1 RHS : _____mm, LHS _____mm Disc : _____mm
- Check and clean disc surface Note : Fill up where applicable
Brake #2 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #3 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #4 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #5 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #6 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #7 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #8 RHS : _____mm, LHS _____mm Disc : _____mm 7. Check AWC condition - Check one way bearing and adjusting nut condition Note : Fill up where applicable
8. Servolifter / Thruster - Inspect oil, electrical and mechanical part Note : Fill up where applicable
9. Structure and limit switch
10. Housekeeping
300
- GANTRY GEARBOX INSPECTION
Description
Location
Observation
Remark
1. Gearbox oil - Inspect oil level and oil condition
All gearboxes
Good(
) / Not Good(
)
All gearboxes
Good(
) / Not Good(
)
All gearboxes
Good(
) / Not Good(
)
All gearboxes
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
2. Structure - Inspect mounting bolts tightness and crack Note : Fill up where applicable 3. Bearing - Inspect abnormal sound Note : Fill up where applicable
4. Temperature (40 ~ 60 degree) Note : Fill up where applicable
5. Coupling - Check rubber insert for coupling condition - Check circlips condition Note : Fill up where applicable
6. Housekeeping
All location
SUPPORTING DOCUMENT
Done(
) / Not Done(
)
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
20 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 3 of 4
310
- GANTRY MOTOR INSPECTION
Description
Location
Observation
Remark
1. Sound inspection - Check any abnormal sound
All motors
Good(
) / Not Good(
)
All motors
Good(
) / Not Good(
)
All motors
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Electrical - Check wire termination at motor termination box
3. Structure - Check cover, mounting and body codition 4. Housekeeping
320 - GANTRY RAIL CLAMP AND ANCHOR PIN INSPECTION
Description
Location
Observation
Remark
1. Rail clamp hydraulic unit - Check oil condition and level - Check piping, any leakage and hose condition
All units
Good(
) / Not Good(
)
All motors
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check wire termination
2. Rail clamp motor - Check any abnormal sound and vibration - Check wire termination
3. Limit switch - Check condition and functionality - Check leakage and mounting condition
4. Structure - Check any leakage and cylinder condition - Check brake shoe / lining condition - Check mounting condition Note : Fill up where applicable
5. Housekeeping
330 - GANTRY ANTI-COLLISION CRANE TO SHIP INSPECTION
Description
Location
Observation
Remark
1. Anti-collision limit switch - Check functionality
Right and left side of boom girder
Good(
) / Not Good(
)
Right and left side of boom girder
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check wire termination and micro switch condition
2. Wire rope - Check wire rope rusty and stringness Note : Fill up where applicable
3. Housekeeping
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
21 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 4 of 4
340
- GANTRY ALARM SYSTEM INSPECTION Description
Location
Observation
Remark
1. Siren - Check siren functionality and condition
All sirens
Good(
) / Not Good(
)
All warning lights
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check wire termination condition
2. Warning light - Check bulb and motor condition - Check lamp cover and mounting condition - Check wire termination condition
3. Housekeeping
350
- GANTRY WHEEL INSPECTION Description
Location
Observation
Remark
1. Wheel - Check wheel bearing condition and abnormal sound
All wheels
Good(
) / Not Good(
)
All wheels
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Structure - Check wheel flange cracks or damages and condition - Check mounting condition
3. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
22 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 1 of 5
360
- BOOM BRAKE INSPECTION
360.1 - SERVICE BRAKE Description
1. Reserve stroke height
Location
Observation
Remark
Brake #1 (Height : _________ mm)
Good(
) / Not Good(
)
Brake #1 (Torque : ________________ Nm)
Good(
) / Not Good(
)
Service brake
Good(
) / Not Good(
)
- Inspect stroke indicator setting and manual release Note : Burbenzer brake 25mm ZPMC brake 10mm
. ra ng orque - Inspect setting and mechanical component Note : IMPSA-A : ≥ 1890Nm, NOELL/MITSUI/ZPMC-A: ≥ 14850 Nm,
IMPSA-B : >7200Nm, ZPMC-B : >5940Nm, ZPMC-C: >6000Nm
3. Air gap - Check any rubbing
Brake pad RHS : ________mm
Good(
) / Not Good(
)
- Check and clean disc surface
Brake pad LHS : ________mm
Good(
) / Not Good(
)
- Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm)
Brake disc
Good(
) / Not Good(
)
Service brake
Good(
) / Not Good(
)
Service brake
Good(
) / Not Good(
)
Service brake
Good(
) / Not Good(
)
Good(
) / Not Good(
)
4. Brake pad and disc
: ________mm
ZPMC (Pad : >3.0 mm, Disc : >1.0mm wear on each side )
5. Check AWC condition - Check one way bearing and adjusting nut condition
6. Check wedge and shackle kit Note : Applicable for Burbenzer brake only
7. Servolifter / Thruster - Inspect oil, electrical and mechanical part
8. Structure - Check pivot pin, linkage and mounting
9. Limit Switch - Check setting and functionality
360.2
a. Brake manual release
Good(
) / Not Good(
)
b. Brake release
Good(
) / Not Good(
)
c. Brake pad wear
Good(
) / Not Good(
)
- EMERGENCY BRAKE Description
Location
Observation
Remark
1. Hydraulic power pack - Check oil condition and working pressure (150-180 bar)
Hydraulic oil tank
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
2. Hydraulic cylinder and block - Check leakage
3. Proximity Sensor & Motor - Check setting and functionality
All location
- Check electrical and mechanical parts
Brake #1 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
- Inspect pad and disc (Pad : ≥ 8 mm, Disc : ≥ 28 mm)
Brake #1 LHS : ______mm
Good(
) / Not Good(
)
- Check and clean disc surface
Brake #2 RHS : ______mm
Good(
) / Not Good(
)
Brake #2 LHS : ______mm
Good(
) / Not Good(
)
Done(
) / Not Done(
)
4. Brake pad and disc
Note : Fill up where applicable
5. Housekeeping
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
23 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 2 of 5
370
- BOOM GEARBOX / REDUCER
Description
Location
Observation
Remark
1. Gearbox oil - Inspect oil level and oil condition
Gearbox #1
Good(
) / Not Good(
)
Gearbox #1
Good(
) / Not Good(
)
Gearbox #1
Good(
) / Not Good(
)
Gearbox #1 : _________degree
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Structure - Inspect mounting bolts tightness and crack
3. Bearing - Inspect abnormal sound
4. Temperature (40 ~ 60 degree)
5. Housekeeping
380 - BOOM MOTOR
Description
1. Sound inspection
Location
Observation
Remark
Boom motor
Good(
) / Not Good(
)
Boom motor
Good(
) / Not Good(
)
Boom emergency motor
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Visual check - Check structure and wire termination
3. Emergency Motor - Check coupling condition - Check limit switch working condition
4. Housekeeping
390
- BOOM WIRE ROPE INSPECTION
Description
Location
Observation
Remark
1. Visual check Wire rope drum
Good(
) / Not Good(
- Broken strands (<18 wires)
Boom tip
Good(
) / Not Good(
)
- Diameter : IMPSA-A : >28.8mm, IMPSA-B : >34.2mm,
A-Frame
Good(
) / Not Good(
)
Length #1
Good(
) / Not Good(
)
Length #2
Good(
) / Not Good(
)
Wire rope
Good(
) / Not Good(
)
All plates
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check broken strands, deformation and kinks
)
ZPMC-A/C : 36mm~33.4mm, ZPMC-B : 32.4mm NOELL/MITSUI : 30mm~2 7.9mm
2. Clips and turnbuckles - Check loosed nut and condition Note : Fill up where applicable
3. Check for lubrication - Check rusty
4. Support plate - Check condition 5. Housekeeping
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
24 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 3 of 5
400 - BOOM WIRE ROPE DRUM INSPECTION
Description
Location
Observation
Remark
1. Check wire rope anchor
All drums
Good(
) / Not Good(
)
2. Check bearing any abnormal noise
All drums
Good(
) / Not Good(
)
3. Check groove surface condition
All drums
Good(
) / Not Good(
)
4. Check structure and mounting
All drums
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
5. Housekeeping
410 - BOOM SHEAVE AND BEARING INSPECTION
Description
1. Check groove condition any damaged or rope trace mark
2. Check locking / keeper plate condition
3. Check bearing condition
4. Structure and mounting - Check condition and bolt tightness 5. Housekeeping
Location
Observation
Remark
Boom tip
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
420 - BOOM MOTOR AND GEARBOX COUPLING INSPECTION
Description
1. Check abnormal sound
Location
Observation
Remark
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Check coupling cover Note : Fill up where applicable
3. Check rubber insert condition Note : Fill up where applicable
4. Structure and mounting - Check bolt tightness and condition 5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
25 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST BOOM : Page 4 of 5
430
- BOOM LIMIT SWITCH INSPECTION Description
Location
Observation
Remark
1. Cable / conduit - Check cable condition, insulation and cable lug
A-Frame
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Limit switch - Check positioning, rusty, functionality and mounting
3. Striker - Check condition
4. Housekeeping
440 - BOOM CAM SWITCH INSPECTION Description
Location
Observation
Remark
1. Cable termination - Check cable damage and breakage at cable lugs
Boom drum
Good(
) / Not Good(
)
All switches
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
Boom drum
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Cam switch functionality - Function test
3. Cam switch coupling tightness - Check bolt tightness
4. Check 3-way gear condition Note : Fill up where applicable
5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
26 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 5 of 5
450
- BOOM LATCH INSPECTION
Description
Location
Observation
Remark
1. Servolifter - Check oil condition and any leakage - Check linkage split-pin and conduit condition
A-Frame
Good(
) / Not Good(
)
All limit switches
Good(
) / Not Good(
)
Boom latch
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check rubber bumper Note : Fill up where applicable
2. Limit Switch - Check condition and functionality Note : Fill up where applicable
3. Structure and mounting - Check condition and bolt tightness Note : Fill up where applicable
4. Plunger - Check plunger and spring condition Note : Fill up where applicable
5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
27 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 1 of 3
460 - EMERGENCY STOP SYSTEM INSPECTION
Description
1. Machinery house - Check functionality and condition Note : Fill up where applicable
2. Trolley - Check functionality and condition Note : Fill up where applicable
3. Boom - Check functionality and condition Note : Fill up where applicable
4. Cabin - Check functionality and condition Note : Fill up where applicable
5. Portal - Check functionality and condition Note : Fill up where applicable
6. Others - Check functionality and condition Note : Fill up where applicable
Location
Observation
Remark
Electrical room (inside)
Good(
) / Not Good(
)
PLC panel
Good(
) / Not Good(
)
DC bus shift cub
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
Trolley / hoist emergency station
Good(
) / Not Good(
)
Trolley house inside
Good(
) / Not Good(
)
Trolley house panel
Good(
) / Not Good(
)
Boom emergency station
Good(
) / Not Good(
)
Boom top outside
Good(
) / Not Good(
)
Boom top inside
Good(
) / Not Good(
)
Boom girder end
Good(
) / Not Good(
)
Checker cabin panel
Good(
) / Not Good(
)
Cabin operator console
Good(
) / Not Good(
)
Boom opeartor cabin
Good(
) / Not Good(
)
Portal landside left
Good(
) / Not Good(
)
Portal landside right
Good(
) / Not Good(
)
Portal seaside left
Good(
) / Not Good(
)
Portal seaside right
Good(
) / Not Good(
)
Gantry operation station
Good(
) / Not Good(
)
High voltage cable reel station
Good(
) / Not Good(
)
TLS station
Good(
) / Not Good(
)
Done(
) / Not Done(
)
7. Housekeeping
All location
470 - FLOODLIGHT INSPECTION
Description
1. Boom floodlight
Location
Observation
Remark
Boom tip
Good(
) / Not Good(
- Check functionality and condition
Boom joint
Good(
) / Not Good(
)
- Check wire termination
Boom center cross beam
Good(
) / Not Good(
)
Boom center
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Operator cabin
Good(
) / Not Good(
)
)
2. Trolley floodlight - Check functionality and condition
)
- Check wire termination Note : Fill up where applicable
3. Machinery house
Seaside
Good(
) / Not Good(
- Check functionality and condition
Right hand side
Good(
) / Not Good(
)
- Check wire termination
Left hand side
Good(
) / Not Good(
)
Landside RHS
Good(
) / Not Good(
)
Landside LHS
Good(
) / Not Good(
)
Note : Fill up where applicable
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
28 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 2 of 3
Description
Location
Observation
Remark
4. Backreach - Check functionality and condition - Check wire termination
Backreach
Good(
) / Not Good(
)
Multi-functional platform
Good(
) / Not Good(
)
Note : Fill up where applicable
5. Portal beam - Check functionality and condition
Right hand side
Good(
) / Not Good(
)
- Check wire termination
Left hand side
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
6. Housekeeping
480
- OPERATOR CABIN INSPECTION
Description
Location
Observation
Remark
1. Master controller / joystick - Check functionality and condition
Right side consol
Good(
) / Not Good(
)
- Check wire termination
Left side consol
Good(
) / Not Good(
)
Wall fan
Good(
) / Not Good(
)
- Check functionality and condition
Cabin lamp
Good(
) / Not Good(
)
- Check wire termination
Power socket
Good(
) / Not Good(
)
- Check power supply functionality
Access gate limit switch
Good(
) / Not Good(
)
Electrical panel
Good(
) / Not Good(
)
- Check functionality and condition
Right side consol
Good(
) / Not Good(
)
- Check wire termination
Left side consol
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
2. Electrical system
3. Selector switch and push button
4. Indicator light - Check functionality and condition - Check wire termination
5. Consol - Check wire termination and condition
Right side consol
Good(
) / Not Good(
)
Left side consol
Good(
) / Not Good(
)
Siren
Good(
) / Not Good(
)
6. Foot siren - Check functionality and condition - Check wire termination
Cabin door
Good(
) / Not Good(
)
- Check structure condition
Access gate
Good(
) / Not Good(
)
- Check wind screen/ glass condition
All bushings
Good(
) / Not Good(
)
Handrail
Good(
) / Not Good(
)
Access ladder
Good(
) / Not Good(
)
Support beam
Good(
) / Not Good(
)
Platform
Good(
) / Not Good(
)
Amplifier and speaker
Good(
) / Not Good(
)
Operator seat
Good(
) / Not Good(
)
7. Structure
8. Public access (PA) system - Check functionality and condition - Check wire termination
9. Operator seat - Check functionality and condition
10. Housekeeping
All location
Done(
SUPPORTING DOCUMENT
) / Not Done(
)
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
29 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 3 of 3
490
- AIR-CONDITIONER INSPECTION Description
Location
Observation
Remark
1. Compressor - Check structure and condition
Control room
Good(
) / Not Good(
)
- Check wire termination and functionality
Operator cabin
Good(
) / Not Good(
)
- Check gas quantity and any leakage
Checker cabin
Good(
) / Not Good(
)
Note : Fill up where applicable
2. Indoor unit - Check structure and condition
Control room
Good(
) / Not Good(
)
- Check wire termination and functionality
Operator cabin
Good(
) / Not Good(
)
Note : Fill up where applicable
Checker cabin
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
3. Tubing and fitting - Check tube condition and any leakage
4. Mechanical part - Check blower motor mounting condition - Check belting condition - Check cleanliness
5. Housekeeping
500
- SOFTWARE AND PROGRAM MONITORING
Please see attachment (if any)
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
30 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
510
- MAIN HOIST SYSTEM GREASING
Description
Location
Observation
Remark
1. Main hoist system - Pump-in new grease into greasing point Note : Fill up where applicable
Spreader cable reel system
Done(
) / Not Done(
)
Headblock sheave
Done(
) / Not Done(
)
Headblock twistlock
Done(
) / Not Done(
)
Backreach-main hoist sheave
Done(
) / Not Done(
)
Trolley platform-main hoist sheave
Done(
) / Not Done(
)
Main hoist drum sheave
Done(
) / Not Done(
)
Done(
) / Not Done(
)
Trolley platform - main hoist rollers
2. Housekeeping
520
All location
- TROLLEY SYSTEM GREASING
Description
Location
Observation
Remark
1. Trolley system - Pump-in new grease into greasing point Note : Fill up where applicable
2. Housekeeping
530
Trolley sheave
Done(
) / Not Done(
Trolley plumber block
Done(
) / Not Done(
) )
Catenary wheel
Done(
) / Not Done(
)
Catenary sheave
Done(
) / Not Done(
)
Catenary McGill guide roller
Done(
) / Not Done(
)
Backreach-catenary sheave
Done(
) / Not Done(
)
Backreach rope tensioner bearing
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
- BOOM SYSTEM GREASING
Description
Location
Observation
Remark
1. Boom system - Pump-in new grease into greasing point Note : Fill up where applicable
2. Housekeeping
General Remark :
Boom drum
Forestay
All location
Done(
) / Not Done(
)
Done(
) / Not Done(
)
Done(
) / Not Done(
)
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
31 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 1 of 3
540
- PASSENGER LIFT INSPECTION
Description
Location
Observation
Remark
1. Guide rail All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
Top of cabin
Good(
) / Not Good(
)
All brakes
Good(
) / Not Good(
)
All floors
Good(
) / Not Good(
)
All push buttons
Good(
) / Not Good(
)
Power cable
Good(
) / Not Good(
)
Carrier
Good(
) / Not Good(
)
Inside carrier
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check buffer spring and rail condition - Check mounting condition
2. Gear - Check rack and pinion gear condition
3. Reduction gear box - Check gearbox condition - Check mounting condition
4. Motor - Check casing and mounting condition
5. Brake - Check functionality and brake condition
6. Cabin level - Check setting on each floor level
7. Push button - Check functionality and condition
8. Cable - Check cable insulation and condition - Check protection rubber and mounting condition
9. Carrier structure - Check door and roof door condition - Check ladder condition
10. Intercomm - Check condition and functionality 11. Housekeeping
550 - FIRE ALARM SYSTEM INSPECTION
Description
Location
Observation
Remark
1. Electrical part - Check AC power LED light up
Machinery house
- Determine standby battery condition ( 25.5 ≤ x ≤ 26.6 Vdc )
- Zone 1
Good(
) / Not Good(
- Check any alarm LED light up from panel
- Zone 2
Good(
) / Not Good(
)
- Fire, Fault, Off, Extinguisher release, Walk test, External
- Zone 3
Good(
) / Not Good(
)
acoustic alarm off, CPU fault, Power supply fault. - Any fault message on the display (Stated the fault message) Note : Fill up where applicable
)
- Zone 4
Good(
) / Not Good(
)
- Main
Good(
) / Not Good(
)
- Charger
Good(
) / Not Good(
)
- Evacuate
Good(
) / Not Good(
)
Good(
) / Not Good(
)
2. Mechanical Part - Visual Check for cylinder pressure gauge reading (±170 bar for 225 bar system) - Examine cylinder valve and hoses for sign of damage, wear or leakage - Inspect all piping & nozzles for any sign damage & leakage Note : Fill up where applicable
Good(
) / Not Good(
)
Good(
) / Not Good(
)
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
32 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 2 of 3
560 - MAINTENANCE HOIST CRANE INSPECTION
Description
Location
Observation
Remark
1. Limit switch and functional test - Hoist up stop
Machinery house
Good(
) / Not Good(
- Hoist up slow down
Machinery house
Good(
) / Not Good(
) )
- Hoist down stop
Machinery house
Good(
) / Not Good(
)
- Trolley forward stop
Machinery house
Good(
) / Not Good(
)
- Trolley forward slow down
Machinery house
Good(
) / Not Good(
)
- Trolley backward stop
Machinery house
Good(
) / Not Good(
)
- Trolley backward slow down
Machinery house
Good(
) / Not Good(
)
- Gantry right stop
Machinery house
Good(
) / Not Good(
)
- Gantry right slow down
Machinery house
Good(
) / Not Good(
)
- Gantry left stop
Machinery house
Good(
) / Not Good(
)
- Gantry left slow down
Machinery house
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
Rubber buffer
Good(
) / Not Good(
)
Hook block
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
Electrical box
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Control console - Check functionality and condition - Check structure
3. Structure - Check structure condition - Check hook and latch condition
4. Wire rope and turn buckle - Check loosed nut and wire rope condition - Check any rusty
5. Electrical part - Check wire termination and contactor condition 6. Housekeeping
570
- AIR COMPRESSOR INSPECTION
Description
Location
Observation
Remark
1. Compressor - Check oil level sufficient, air filter, V-belt, pressure gauge,
Machinery house
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
safety valve, piping and mounting condition - Check any abnormal sound or vibration
2. Pressure Switch - Check pressure setting Note : Cut in: 9.9 kg/cm2 & Cut out: 8.0 kg/cm2 - Adjusting screw locknut and check wire termination
3. Motor - Check mounting and any abnormal sound
4. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
33 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST AUXILARY : Page 3 of 3
580 - QC CHECKER CABIN INSPECTION Description
Location
Observation
Remark
1. Socket & power supply - Check mounting and condition
2. Check lighting condition and functionality
All location
Good(
) / Not Good(
)
Cabin ceiling
Good(
) / Not Good(
)
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
3. Intercomm - Check condition and functionality
4. Structure - Check mounting and condition - Check door and glass
5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
34 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM: Page 1 of 1
590
- BOOM FORESTAY INSPECTION
Description
Location
Observation
Remark
1. Bushing - Check abnormal sound and vibration
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All supports
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Structure and mounting - Check condition and mounting
3. Rest support - Check forestay rest support condition
4. Boom buffer - Check condition and mounting
5. Housekeeping
600
- BOOM SHEAVE INSPECTION
Description
Location
Observation
Remark
1. Check bearing condition
All sheaves
Good(
) / Not Good(
)
2. Check grove condition
All sheaves
Good(
) / Not Good(
)
All sheaves
Good(
) / Not Good(
)
All sheaves
Done(
) / Not Done(
)
3. Structure - Check mounting and condition
4. Housekeeping
610
- BOOM CABIN INSPECTION
Description
Location
Observation
Remark
1. Indicator bulb - Check condition and functionality
2. Check lighting condition and functionality
All indicators bulbs
Good(
) / Not Good(
)
Cabin ceiling
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Done(
) / Not Done(
)
3. Structure - Check mounting and condition - Check door and glass
4. Intercomm - Check condition and functionality
5. Housekeeping
General Remark :
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
35 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
620
- GANTRY SYSTEM GREASING
Description
Location
Observation
Remark
1. Gantry system - Pump-in new grease into greasing point
2. Housekeeping
630
All boggies
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
- BOOM SYSTEM GREASING
Description
Location
Observation
Remark
1. Boom system - Pump-in new grease into greasing point
2. Housekeeping
All boom sheaves
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
640 - MAIN HOIST WIRE ROPE LUBRICATION
Description
Location
Observation
Remark
1. Main hoist wire rope - Check condition and lubricate wire rope
2. Housekeeping
650
All main hoist wire ropes
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
- TROLLEY WIRE ROPE LUBRICATION
Description
Location
Observation
Remark
1. Trolley wire rope - Check condition and lubricate wire rope
All trolley wire ropes
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
2. Housekeeping
660
- BOOM WIRE ROPE LUBRICATION
Description
Location
Observation
Remark
1. Boom wire rope - Check condition and lubricate wire rope
2. Housekeeping
670
All boom wire ropes
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
- CATERNARY WIRE ROPE LUBRICATION
Description
Location
Observation
Remark
1. Catenary wire rope - Check condition and lubricate wire rope Note : Fill up where applicable
All caternary wire ropes
Done(
) / Not Done(
)
2. Housekeeping
Done(
All location
SUPPORTING DOCUMENT
) / Not Done(
)
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
36 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 1 of 1
680 - MAIN CABLE REEL INSPECTION Description
Location
Observation
Remark
1. Motor - Check mounting and condition
Main cable reel motor
Good(
) / Not Good(
)
Main power cable
Good(
) / Not Good(
)
All mounting
Good(
) / Not Good(
)
Good(
) / Not Good(
)
2. Main cable - Check cable condition
3. Structure - Check mounting and condition
4. Slip ring - Check slip rings condition
5. Gearbox - Check gearbox oil condition
Good(
) / Not Good(
)
- Check mounting and condition
Good(
) / Not Good(
)
- Check any abnormal sound
Good(
) / Not Good(
)
Done(
) / Not Done(
)
6. Housekeeping
General Remark :
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
37 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
690
- BOOM BACKSTAY GREASING
Description
Location
Observation
Remark
1. Boom backstay - Pump-in new grease into greasing point
All greasing points
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
2. Housekeeping
700
- KBT COUPLING GREASING Description
Location
Observation
Remark
1. KBT coupling - Pump-in new grease into greasing point
Done(
) / Not Done(
)
Done(
) / Not Done(
)
Note : Fill up where applicable Please see attachment (No. :
2. Housekeeping
General Remark :
)
All location
Document No.
SUPPORTING DOCUMENT
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
38 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AC/DC MEGGER : Page 1 of 1
710
- MAIN HOIST AC & DC MOTOR INSULATION READING
Note : Fill up where applicable Please see attachment (No. :
720
)
- TROLLEY AC & DC MOTOR INSULATION READING
Note : Fill up where applicable Please see attachment (No. :
730
)
- BOOM AC & DC MOTOR INSULATION READING
Note : Fill up where applicable Please see attachment (No. :
740
)
- GANTRY AC & DC MOTOR INSULATION READING
Please see attachment (No. :
General Remark :
)
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
1 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST MONTH / YEAR
:
CRANE NUMBER
:
JOB NUMBER
:
W.O. NUMBER
:
DATE /TIME START : DATE/TIME END
:
HOUR METER READING : CRANE
:
MAIN HOIST
:
LAND SIDE (FOR DUAL HOIST CRANE)
SEA SIDE (FOR DUAL HOIST CRANE)
TROLLEY
:
GANTRY
:
BOOM
:
PM CHECKLIST TYPE : Please tick ( X ) where applicable :
MONTHLY PM
:
Page 1 to page 30
(
)
QUARTERLY PM
:
Page 1, page 31 to page 36
(
)
SEMI-ANNUALLY PM :
Page 1, page 37 to page 38
(
)
ANNUALLY PM
Page 1 to page 38
(
)
SYSTEM :
:
PREPARED BY :
SIGNATURE :
MAIN HOIST SYSTEM Date :
TROLLEY SYSTEM Date :
GANTRY SYSTEM Date :
BOOM SYSTEM Date :
AUXIALLARY SYSTEM Date :
GREASING Date :
VERIFIED BY :
SIGNATURE :
Date :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
2 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 1 of 8
10
- MAIN HOIST BRAKE
10.1 - SERVICE BRAKE
Description
Location
Observation
Remark
Brake #1 (Height : _________ mm)
Good(
) / Not Good(
)
- Inspect stroke indicator setting and manual release
Brake #2 (Height : _________ mm)
Good(
) / Not Good(
)
Note : Fill up where applicable
Brake #3 (Height : _________ mm)
Good(
) / Not Good(
)
Brake #4 (Height : _________ mm)
Good(
) / Not Good(
)
1. Reserve stroke height (10 mm)
. ra ng orque
Brake #1 (Torque : ________________ Nm)
Good(
) / Not Good(
)
- Inspect setting and mechanical component
Brake #2 (Torque : ________________ Nm)
Good(
) / Not Good(
)
Note : IMPSA-A :≥ 15.75kNm, NOELL/MITSUI : ≥ 14.85kNm,
Brake #3 (Torque : ________________ Nm)
Good(
) / Not Good(
)
Brake #4 (Torque : ________________ Nm)
Good(
) / Not Good(
)
All brakes
Good(
) / Not Good(
)
IMPSA-B : 27kNm, ZPMC-A : 12.6kNm ZPMC-A : ≥ 14.85kNm, ZPMC-C : 19kNm
3. Air gap - Check any rubbing
Brake #1 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
- Inspect pad and disc
Brake #1 LHS : ______mm
Good(
) / Not Good(
)
- Check and clean disc surface
Brake #2 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Note : Fill up where applicable
Brake #2 LHS : ______mm
Good(
) / Not Good(
)
All cranes (Pad : ≥ 5 mm, Disc : ≥ 27 mm)
Brake #3 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
ZPMC-B (Pad : ≥ 3 mm, Disc :≤1.0mm wear)
Brake #3 LHS : ______mm
Good(
) / Not Good(
)
ZPMC-C (Pad : > 3 mm, Disc wear more than 20%)
Brake #4 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #4 LHS : ______mm
Good(
) / Not Good(
)
Brake #1
Good(
) / Not Good(
)
Brake #2
Good(
) / Not Good(
)
Brake #3
Good(
) / Not Good(
)
Brake #4
Good(
) / Not Good(
)
Brake #1
Good(
) / Not Good(
)
Brake #2
Good(
) / Not Good(
)
Brake #3
Good(
) / Not Good(
)
Brake #4
Good(
) / Not Good(
)
All servolifters
Good(
) / Not Good(
)
Good(
) / Not Good(
)
4. Brake pad and disc
5. Check AWC condition - Check one way bearing and adjusting nut condition
6. Check wedge and shackle kit Note : Fill up where applicable
7. Servolifter / Thruster - Inspect oil, electrical and mechanical part
8. Structure - Check pivot pin, linkage and mounting
9. Limit Switch - Check setting and functionality Note : Fill up where applicable
10. Housekeeping
General Remark :
a. Brake manual release
Good(
) / Not Good(
)
b. Brake release
Good(
) / Not Good(
)
c. Brake pad wear
Good(
) / Not Good(
)
Done(
) / Not Done(
)
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
3 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 2 of 8
10.2 - EMERGENCY BRAKE
Description
Location
Observation
Remark
1. Hydraulic power pack Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Brake #1 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #1 LHS : ______mm
Good(
) / Not Good(
)
Brake #2 RHS : ______mm
Good(
) / Not Good(
)
Brake #2 LHS : ______mm
Good(
) / Not Good(
)
Brake #3 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #3 LHS : ______mm
Good(
) / Not Good(
)
Brake #4 RHS : ______mm
Good(
) / Not Good(
)
Brake #4 LHS : ______mm
Good(
) / Not Good(
)
Brake #5 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #5 LHS : ______mm
Good(
) / Not Good(
)
Brake #6 RHS : ______mm
Good(
) / Not Good(
)
Brake #6 LHS : ______mm
Good(
) / Not Good(
)
Brake #7 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #7 LHS : ______mm
Good(
) / Not Good(
)
Brake #8 RHS : ______mm
Good(
) / Not Good(
)
Brake #8 LHS : ______mm
Good(
) / Not Good(
)
Done(
) / Not Done(
)
- Check oil condition and working pressure (150-180 bar)
2. Hydraulic cylinder and block - Check leakage
3. Proximity sensor - Check setting and functionality Note : Fill up where applicable
4. Motor - Check electrical and mechanical parts
5. Brake pad and disc - Inspect pad and disc (Pad : ≤ 8 mm, Disc : ≥ 28 mm)
- Check and clean disc surface Note : Fill up where applicable
6. Housekeeping
General Remark :
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
4 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 3 of 8
20 - MAIN HOIST GEARBOX / REDUCER
Description
Location
Observation
Remark
1. Gearbox oil - Inspect oil level and oil condition Note : Fill up where applicable
Gearbox #1
Good(
) / Not Good(
)
Gearbox #2
Good(
) / Not Good(
)
Gearbox #1
Good(
) / Not Good(
)
Gearbox #2
Good(
) / Not Good(
)
2. Structure - Inspect mounting bolts tightness and crack Note : Fill up where applicable 3. Bearing - Inspect abnormal sound Note : Fill up where applicable
4. Temperature (40 ~ 60 degree) Note : Fill up where applicable 5. Housekeeping
Gearbox #1
Good(
) / Not Good(
)
Gearbox #2
Good(
) / Not Good(
)
Gearbox #1 : _________degree
Good(
) / Not Good(
)
Gearbox #2 : _________degree
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
30 - MAIN HOIST AC AND DC MOTOR
Description
1. Sound inspection Note : Fill up where applicable
2. Check heater Note : For DC motor only
Location
Observation
Remark
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
Motor #3
Good(
) / Not Good(
)
Motor #4
Good(
) / Not Good(
)
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
Motor #3
Good(
) / Not Good(
)
Motor #4
Good(
) / Not Good(
)
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
Good(
) / Not Good(
)
3. Visual check - Check armature winding for burn marks, scratches and damages (For DC motor only) - Check structure and wire termination Note : Fill up where applicable
4. Check motor in running condition for sparks Note : For DC motor only
5. Emergency Motor - Check coupling condition - Check limit switch working condition
6. Carbon Brush and Holder - Check length and condition Note : For DC motor only
7. Housekeeping
Motor #1 - Top (8 pcs)
Good(
) / Not Good(
)
Motor #1 - Bottom (8 pcs)
Good(
) / Not Good(
)
Motor #1 - Right (8 pcs)
Good(
) / Not Good(
)
Motor #1 - Left (8 pcs)
Good(
) / Not Good(
)
Motor #2 - Top (8 pcs)
Good(
) / Not Good(
)
Motor #2 - Bottom (8 pcs)
Good(
) / Not Good(
)
Motor #2 - Right (8 pcs)
Good(
) / Not Good(
)
Motor #2 - Left (8 pcs)
Good(
) / Not Good(
)
Done(
) / Not Done(
)
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
5 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 4 of 8
40 - MAIN HOIST WIRE ROPE INSPECTION
Description
Location
Observation
Remark
1. Visual check - Check broken strands, deformation and kinks
Drum
Good(
) / Not Good(
- Diameter (NOELL/ZPMC-A : 26.2mm~28.0mm)
Backreach
Good(
) / Not Good(
) )
- Diameter (IMPSA : 26.7mm~28.5mm)
Trolley platform
Good(
) / Not Good(
)
- Diameter (MITSUI : 26.2mm~23.3mm)
Headblock
Good(
) / Not Good(
)
Length #1
Good(
) / Not Good(
)
Length #2
Good(
) / Not Good(
)
Length #3
Good(
) / Not Good(
)
Length #4
Good(
) / Not Good(
)
- Diameter (ZPMC-C : 32.00mm~29.76mm) - Broken strands (<18 wires) Note : Fill up where applicable
2. Clips and turnbuckles - Check loosed nut and condition
3. Check for lubrication - Check rusty
Length #1
Good(
) / Not Good(
)
Length #2
Good(
) / Not Good(
)
Length #3
Good(
) / Not Good(
)
Length #4
Good(
) / Not Good(
)
All rollers and plates
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
4. Support roller and plate - Check condition
5. Housekeeping
50 - MAIN HOIST WIRE ROPE DRUM INSPECTION
Description
Location
Observation
Remark
1. Check wire rope anchor
All drums
Good(
) / Not Good(
)
2. Check bearing any abnormal noise
All drums
Good(
) / Not Good(
)
3. Check groove surface condition
All drums
Good(
) / Not Good(
)
4. Check structure and mounting
All drums
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
6 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 5 of 8
60 - MAIN HOIST SHEAVE AND BEARING INSPECTION
Description
1. Check groove condition any damaged or rope trace mark Note : Fill up where applicable
2. Check locking / keeper plate condition Note : Fill up where applicable
3. Check bearing condition Note : Fill up where applicable
4. Housekeeping
Location
Observation
Remark
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Headblock
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Headblock
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Headblock
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
70 - MAIN HOIST MOTOR AND GEARBOX COUPLING INSPECTION
Description
1. Check abnormal sound
Location
Observation
Remark
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Check coupling cover Note : Fill up where applicable
3. Check rubber insert condition Note : Fill up where applicable
4. Structure - Check bolt tightness and condition
5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
7 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 6 of 8
80 - MAIN HOIST CAM SWITCH INSPECTION
Description
Location
Observation
Remark
1. Cable termination - Check cable damage and breakage at cable lugs
Main hoist drum
Good(
) / Not Good(
)
All switches
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
Main hoist drum
Good(
) / Not Good(
)
Main hoist drum
Good(
) / Not Good(
)
Main hoist drum
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Cam switch functionality - Function test
3. Cam switch coupling tightness - Check bolt tightness Note : Fill up where applicable
4. Check 3-way gear condition Note : Fill up where applicable
5. Driven belt / driven chain - Check belting condition and any crack Note : Fill up where applicable
6. Driven pulley - Check pulley mounting, side guide, wear and crack Note : Fill up where applicable
7. Housekeeping
90 - MAIN HOIST LIMIT SWITCH INSPECTION
Description
Location
Observation
Remark
1. Cable / conduit - Check cable condition, insulation and cable lug
Trolley platform / trolley house
Good(
) / Not Good(
)
Trolley platform / trolley house
Good(
) / Not Good(
)
Trolley platform / trolley house
Good(
) / Not Good(
)
Spreader cable / headblock
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Limit switch - Check positioning, rusty, functionality and mounting
3. Counter weight - Check condition Note : Fill up where applicable
4. Striker - Check condition Note : Fill up where applicable
5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
8 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 7 of 8
100 - MAIN HOIST ENCODER INSPECTION
Description
Location
Observation
Remark
1. Coupling - Check mounting, rusty, alignment and sprider wear
Main hoist motor and drum
Good(
) / Not Good(
)
Main hoist drum
Good(
) / Not Good(
)
Main hoist drum
Good(
) / Not Good(
)
Main hoist drum
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
2. Driven belt / driven chain - Check belting condition and any crack Note : Fill up where applicable
3. Driven pulley - Check pulley mounting, side guide, wear and crack Note : Fill up where applicable
4. Electrical - Check cable connection
5. Housekeeping
110 - MAIN HOIST OVER SPEED DETECTOR INSPECTION
Description
Location
Observation
Remark
1. Cable termination - Check cable damage and breakage at cable lugs
Main hoist drum
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
Main hoist drum
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Coupling tightness - Check bolt tightness
3. Check 3-way gear condition Note : Fill up where applicable
4. Housekeeping
120 - SPREADER CABLE REEL INSPECTION
Description
Location
Observation
Remark
1. Spreader drum - Check drum condition
Trolley platform / trolley house
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Trolley platform / trolley house
Good(
) / Not Good(
)
Trolley platform / trolley house
Good(
) / Not Good(
)
- Check cable condition
2. Driven belt / driven chain (cam switch) - Check belting condition and any crack Note : Fill up where applicable
3. Driven pulley (cam switch) - Check pulley mounting, side guide, wear and crack Note : Fill up where applicable
4. Electrical - Check cable connection and slip ring carbon brushes - Check short length cable and junction box
Trolley platform / trolley house
Good(
) / Not Good(
)
Headblock
Good(
) / Not Good(
)
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
9 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
HOIST : Page 8 of 8
Description
Location
Observation
Remark
5. Limit switch - Check limit switch condition
Trolley platform / trolley house
Good(
) / Not Good(
)
Headblock
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
6. Absorber - Check condition
7. Housekeeping
130 - SPREADER HEADBLOCK INSPECTION
Description
Location
Observation
Remark
1. Twistlock - Check gap, lock pin and condition
All twistlocks
Good(
) / Not Good(
)
Headblock lock/unlock lever
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Done(
) / Not Done(
)
2. Electrical - Check limit switch and functionality
3. Structure - Check condition, ladder, hand rail and grating
4. Housekeeping
All location
140 - TRIM, LIST AND SKEW (TLS) SYSTEM INSPECTION
Description
Location
Observation
Remark
1. Power pack - Check oil level, condition and cleanliness - Check working pressure (160±10 psi) - Check hose, valve and piping
Backreach / TLS platform / trolley house
Good(
) / Not Good(
)
Pressure : _________ psi
Good(
) / Not Good(
)
Backreach / TLS platform / trolley house
Good(
) / Not Good(
)
All cylinders
Good(
) / Not Good(
)
All motors and pumps
Good(
) / Not Good(
)
All control boxes
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Hydraulic cylinder - Check oil leak, guide roller and condition
3. Positioner sensor - Check wire string, mounting and crack
4. Motor and pump - Check abnormal sound, overheating, and cover - Check electrical connection
5. TLS control panel - Check wire termination, conduit and DC supply - Check door and lock condition
6. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
10 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 1 of 8
150
- TROLLEY BRAKE INSPECTION
Description
1. Reserve stroke height (10 mm) - Inspect stroke indicator setting and manual release Note : Fill up where applicable
. ra ng orque
Location
Observation
Remark
Brake #1 (Height : _________ mm)
Good(
) / Not Good(
)
Brake #2 (Height : _________ mm)
Good(
) / Not Good(
)
Brake #3 (Height : _________ mm)
Good(
) / Not Good(
)
Brake #4 (Height : _________ mm)
Good(
) / Not Good(
)
Brake #1 (Torque : ________________ Nm)
Good(
) / Not Good(
)
- Inspect setting and mechanical component
Brake #2 (Torque : ________________ Nm)
Good(
) / Not Good(
)
Note : IMPSA-A : ≥ 977Nm, NOELL /MITSUI/ZPMC-A : ≥ 1890Nm
Brake #3 (Torque : ________________ Nm)
Good(
) / Not Good(
)
IMPSA-B : ≥ 977Nm , ZPMC-B : ≥ 5175 Nm, ZPMC-C : 5500Nm
Brake #4 (Torque : ________________ Nm)
Good(
) / Not Good(
)
All brakes
Good(
) / Not Good(
)
Brake #1 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #1 LHS : ______mm
Good(
) / Not Good(
)
ZPMC-C: Disk wear >20% from 30mm, Pad >3mm
Brake #2 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
ZPMC(Pad : ≥ 3 mm, Disc : ≤ 1.0mm wear on each side)
Brake #2 LHS : ______mm
Good(
) / Not Good(
)
Brake #3 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #3 LHS : ______mm
Good(
) / Not Good(
)
Brake #4 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #4 LHS : ______mm
Good(
) / Not Good(
)
Brake #1
Good(
) / Not Good(
)
Brake #2
Good(
) / Not Good(
)
Brake #3
Good(
) / Not Good(
)
Brake #4
Good(
) / Not Good(
)
Brake #1
Good(
) / Not Good(
)
Brake #2
Good(
) / Not Good(
)
Brake #3
Good(
) / Not Good(
)
Brake #4
Good(
) / Not Good(
)
All servolifters
Good(
) / Not Good(
)
Good(
) / Not Good(
)
3. Air gap - Check any rubbing
4. Brake pad and disc - Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm)
- Check and clean disc surface Note : Fill up where applicable
5. Check AWC condition - Check one way bearing and adjusting nut condition Note : Fill up where applicable
6. Check wedge and shackle kit Note : Fill up where applicable
7. Servolifter / Thruster - Inspect oil, electrical and mechanical part
8. Structure - Check pivot pin, linkage and mounting
9. Limit Switch - Check setting and functionality Note : Fill up where applicable
10. Housekeeping
General Remark :
a. Brake manual release
Good(
) / Not Good(
)
b. Brake release
Good(
) / Not Good(
)
c. Brake pad wear
Good(
) / Not Good(
)
Done(
) / Not Done(
)
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
11 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 2 of 8
160 - TROLLEY GEARBOX INSPECTION
Description
Location
Observation
Remark
Gearbox #1
Good(
) / Not Good(
)
- Inspect oil level and oil condition
Gearbox #2
Good(
) / Not Good(
)
Note : Fill up where applicable
Gearbox #3
Good(
) / Not Good(
)
Gearbox #4
Good(
) / Not Good(
)
1. Gearbox oil
2. Structure - Inspect mounting bolts tightness and crack Note : Fill up where applicable
3. Bearing - Inspect abnormal sound Note : Fill up where applicable
4. Temperature (40 ~ 60 degree) Note : Fill up where applicable
5. Housekeeping
Gearbox #1
Good(
) / Not Good(
)
Gearbox #2
Good(
) / Not Good(
)
Gearbox #3
Good(
) / Not Good(
)
Gearbox #4
Good(
) / Not Good(
)
Gearbox #1
Good(
) / Not Good(
)
Gearbox #2
Good(
) / Not Good(
)
Gearbox #3
Good(
) / Not Good(
)
Gearbox #4
Good(
) / Not Good(
)
Gearbox #1 : _________degree
Good(
) / Not Good(
)
Gearbox #2 : _________degree
Good(
) / Not Good(
)
Gearbox #3 : _________degree
Good(
) / Not Good(
)
Gearbox #4 : _________degree
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
170 - TROLLEY MOTOR INSPECTION
Description
Location
Observation
Remark
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
Motor #3
Good(
) / Not Good(
)
Motor #4
Good(
) / Not Good(
)
Note : For DC motor only
Motor #1
Good(
) / Not Good(
)
Note : Fill up where applicable
Motor #2
Good(
) / Not Good(
)
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
Motor #3
Good(
) / Not Good(
)
Motor #4
Good(
) / Not Good(
)
Motor #1
Good(
) / Not Good(
)
Motor #2
Good(
) / Not Good(
)
1. Sound inspection Note : Fill up where applicable
2. Check heater condition
3. Visual check - Check armature winding for burn marks, scratches and damages (For DC motor only) - Check structure and wire termination Note : Fill up where applicable
4. Check motor in running condition for sparks Note : For DC motor only
5. Emergency motor - Check coupling condition
Motor #1
Good(
) / Not Good(
)
- Check limit switch working condition
Motor #2
Good(
) / Not Good(
)
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
12 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 3 of 8
Description
6. Carbon brush and holder - Check length and condition Note : For DC motor only
Location
Remark
Motor #1 - Top (3 pcs)
Good(
) / Not Good(
)
Motor #1 - Bottom (3 pcs)
Good(
) / Not Good(
)
Motor #1 - Right (3 pcs)
Good(
) / Not Good(
)
Motor #1 - Left (3 pcs)
Good(
) / Not Good(
)
Motor #2 - Top (3 pcs)
Good(
) / Not Good(
)
Motor #2 - Bottom (3 pcs)
Good(
) / Not Good(
)
Motor #2 - Right (3 pcs)
Good(
) / Not Good(
)
Motor #2 - Left (3 pcs)
Good(
) / Not Good(
)
All location
7. Housekeeping
Observation
Done(
) / Not Done(
)
180 - TROLLEY WIRE ROPE INSPECTION
Description
Location
Observation
Remark
1. Visual check - Check broken strands, deformation and kinks
Drum
Good(
) / Not Good(
- Diameter (2 6.2mm~mm)
Backreach
Good(
) / Not Good(
)
- Broken strands (<18 wires)
Trolley platform
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Length #1
Good(
) / Not Good(
)
Length #2
Good(
) / Not Good(
)
Note : Fill up where applicable
2. Clips and turnbuckles - Check loosed nut and condition
3. Check for lubrication - Check rusty
)
Length #1
Good(
) / Not Good(
)
Length #2
Good(
) / Not Good(
)
All rollers and plates
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
4. Support roller and plate - Check condition
5. Housekeeping
190 - TROLLEY WIRE ROPE DRUM INSPECTION
Description
Location
Observation
Remark
1. Check wire rope anchor
All drums
Good(
) / Not Good(
)
2. Check bearing any abnormal noise
All drums
Good(
) / Not Good(
)
3. Check groove surface condition
All drums
Good(
) / Not Good(
)
4. Check structure and mounting
All drums
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
13 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 4 of 8
200 - TROLLEY SHEAVE AND BEARING INSPECTION
Description
1. Check groove condition any damaged or rope trace mark Note : Fill up where applicable
2. Check locking / keeper plate condition Note : Fill up where applicable
3. Check bearing condition Note : Fill up where applicable
4. Housekeeping
Location
Observation
Remark
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
Backreach
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
210 - TROLLEY MOTOR AND GEARBOX COUPLING INSPECTION
Description
1. Check abnormal sound
Location
Observation
Remark
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
2. Check coupling cover Note : Fill up where applicable
3. Check rubber insert condition Note : Fill up where applicable
4. Structure - Check bolt tightness and condition
220 - TROLLEY WHEEL INSPECTION
Description
1. Wheel - Check wheel bearing condition and abnormal sound
2. Structure - Check wheel flange cracks or damages and condition
3. Guide roller - Check bearing and guide roller condition
Location
Observation
Remark
Wheel #1
Good(
) / Not Good(
)
Wheel #2
Good(
) / Not Good(
)
Wheel #3
Good(
) / Not Good(
)
Wheel #4
Good(
) / Not Good(
)
Wheel #1
Good(
) / Not Good(
)
Wheel #2
Good(
) / Not Good(
)
Wheel #3
Good(
) / Not Good(
)
Wheel #4
Good(
) / Not Good(
)
Wheel #1
Good(
) / Not Good(
)
Wheel #2
Good(
) / Not Good(
)
Wheel #3
Good(
) / Not Good(
)
Wheel #4
Good(
) / Not Good(
)
Document No.
SUPPORTING DOCUMENT
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
14 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST TROLLEY : Page 5 of 8
Description
4. Floating shaft - Check coupling condition and bolt tighness Note : Fill up where applicable
5. Plumber block - Chek abnormal sound Note : Fill up where applicable
6. Housekeeping
Location
Observation
Remark
Floating shaft LHSS
Good(
) / Not Good(
)
Floating shaft LHLS
Good(
) / Not Good(
)
Floating shaft RHLS
Good(
) / Not Good(
)
Floating shaft RHSS
Good(
) / Not Good(
)
Plumber block LHSS
Good(
) / Not Good(
)
Plumber block LHLS
Good(
) / Not Good(
)
Plumber block RHLS
Good(
) / Not Good(
)
Plumber block RHSS
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
230 - TROLLEY RAIL INSPECTION
Description
Location
Observation
Remark
1. Trolley rail structure
- Check greasy or oily
All
Good(
) / Not Good(
- Check rail clip, bolt and nut
All
Good(
) / Not Good(
)
- Check welded part cracked or chipped
All
Good(
) / Not Good(
)
- Check side plate bolt tightness
Boom joint
Good(
) / Not Good(
)
- Check trolley rail gap
Boom joint
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Housekeeping
)
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
15 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 6 of 8
240 - TROLLEY LIMIT SWITCH INSPECTION
Description
Location
Observation
Remark
1. Cable and conduit Good(
) / Not Good(
)
All limit switches
Good(
) / Not Good(
)
All flag sensors
Good(
) / Not Good(
)
- Check insulation, termination and condition
2. Limit switch - Check condtion, mounting and functionality 3. Flag sensor - Check condtion, mounting and functionality
4. Slowdown magnet - Check condtion, mounting and functionality
5. Housekeeping
Boom tip
Good(
) / Not Good(
)
Backreach
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
250 - TROLLEY ENCODER INSPECTION
Description
Location
Observation
Remark
1. Coupling - Check mounting, rusty, alignment and sprider wear
Trolley motor
Good(
) / Not Good(
)
Trolley motor
Good(
) / Not Good(
)
Trolley LS LHS
Good(
) / Not Good(
)
Trolley motor
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
2. Electrical - Check cable connection
3. Structure - Check mounting, wheel and bearing condition Note : Fill up where applicable
4. Encoder sensor - Check sensor surface and condition
3. Housekeeping
260 - TROLLEY CATENARY INSPECTION
Description
Location
Observation
Remark
1. Wheel bearings - Check abnormal noise
All location
Good(
) / Not Good(
)
2. Trolley wheel - Check any crack or damage on wheel flange
All wheels
Good(
) / Not Good(
)
- Check wheel bracket bolts tighten
All wheel brackets
Good(
) / Not Good(
)
- Check wheel cover bolt tightness
All bolts
Good(
) / Not Good(
)
Note : Fill up where applicable
3. Sheave and bearing - Check groove condition
1. Boom tip LHS and RHS
Good(
) / Not Good(
)
- Check sheave bearing abnormal sound and condition
2. Catenary LS LHS and RHS
Good(
) / Not Good(
)
- Check locking /keeper plate bolts and nuts condition
3. Catenary SS LHS and RHS
Good(
) / Not Good(
)
4. Backreach LHS and RHS
Good(
) / Not Good(
)
Note : Fill up where applicable
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
16 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 7 of 8
Description
Location
Observation
Remark
4. Catenary wire rope - Visual check for wear, deformation and kinks Note : Fill up where applicable
1. Drive rope LHS and RHS
Good(
) / Not Good(
)
2. Tie rope LHS and RHS
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
5. Clip and turnbuckle - Check clips and turnbuckles condition Note : Fill up where applicable
6. Structure - Check catenary structure condition Note : Fill up where applicable
1. Catenary LHS
Good(
) / Not Good(
)
2. Catenary RHS
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
7. Guide roller - Check guide roller tighness and condition
8. Support roller - Check support roller, bearing and shaft condition
9. Housekeeping
270 - TROLLEY WIRE ROPE TENSIONER INSPECTION
Description
Location
Observation
Remark
1. Cylinder - Check abnormal sound and cylinder condition - Check hose and any leakage
All cylinders
Good(
) / Not Good(
)
Note : Fill up where applicable
2. Cross joint - Check vibration and any abnormal sound
All location
Good(
) / Not Good(
)
- Check bearing and shaft condition
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All limit switches
Good(
) / Not Good(
)
All limit switches
Good(
) / Not Good(
)
All power units
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
3. Sheave - Check bolt tighness, sheave and bearing condition
4. Limit switch - Check limit switch condition and functionality
5. Hydraulic power pack - Check tank, hose and fitting condition - Check any leakage and oil level
6. Power unit for motor pump - Check abnormal sound, termination and condition
7. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
17 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
TROLLEY : Page 8 of 8
280
- FESTOON SYSTEM INSPECTION
Description
Location
Observation
Remark
1. Festoon rail - Check deformation, dents and leveling condition
Along rails
Good(
) / Not Good(
)
All cables
Good(
) / Not Good(
)
All shackles and elastic cords
Good(
) / Not Good(
)
All bumpers
Good(
) / Not Good(
)
All rollers
Good(
) / Not Good(
)
Motor #1 and #2
Good(
) / Not Good(
)
Motor #1 and #2
Good(
) / Not Good(
)
Trolley platform
Good(
) / Not Good(
)
All carrier
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Festoon cable - Check cable and cable clamp mouting condition
3. Sling shackle and elastic cord - Check any cut, broken and wear condition - Check sling shackle missing and condition
4. Festoon bumper - Check mounting and bumber condition
5. Side roller, runner wheel and anti-lift roller - Check roller condition and abnormal sound - Check mounting condition
6. Belting system - Check belting, pulley and bearing condition Note : Fill up where applicable
7. Motor (Brand : VAHLE or WAMPFLER) - Check abnormal sound and mounting condition - Check bolt tightness and motor cover condition Note : Fill up where applicable
8. Trolley festoon box - Check cable termination and slot connection condition - Check door seal condition
9. Festoon carrier - Check carrier condition
10. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
18 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 1 of 4
290 - GANTRY BRAKE INSPECTION
Description
Location
Observation
Remark
1. Gantry brake - Check wire termination - Check friction disc, stationary disc and coil assembly
All brakes
Good(
) / Not Good(
)
- Check mounting cover and silicon seal condition Note : Fill up where applicable
2. Reserve stroke height (10 mm) - Inspect stroke indicator setting and manual release Note : Fill up where applicable
Lanside Height : #1 : ______ mm
#5 : ______ mm)
Good(
) / Not Good(
)
Height : #2 : ______ mm
#6 : ______ mm)
Good(
) / Not Good(
)
Height : #3 : ______ mm
#7 : ______ mm)
Good(
) / Not Good(
)
Height : #4 : ______ mm
#8 : ______ mm)
Good(
) / Not Good(
)
Height : #1 : ______ mm
#5 : ______ mm)
Good(
) / Not Good(
)
Height : #2 : ______ mm
#6 : ______ mm)
Good(
) / Not Good(
)
Height : #3 : ______ mm
#7 : ______ mm)
Good(
) / Not Good(
)
Height : #4 : ______ mm
#8 : ______ mm)
Good(
) / Not Good(
)
Seaside
.
Lanside - Inspect setting and mechanical component
Torque : #1 : ______ Nm
#5 : ______ Nm)
Good(
) / Not Good(
)
Note : Fill up where applicable
Torque : #2 : ______ Nm
#6 : ______ Nm)
Good(
) / Not Good(
)
Torque : #3 : ______ Nm
#7 : ______ Nm)
Good(
) / Not Good(
)
Torque : #4 : ______ Nm
#8 : ______ Nm)
Good(
) / Not Good(
)
Torque : #1 : ______ Nm
#5 : ______ Nm)
Good(
) / Not Good(
)
Torque : #2 : ______ Nm
#6 : ______ Nm)
Good(
) / Not Good(
)
Torque : #3 : ______ Nm
#7 : ______ Nm)
Good(
) / Not Good(
)
Torque : #4 : ______ Nm
#8 : ______ Nm)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
IMPSA-B : > 207Nm, ZPMC-B : >320Nm, ZPMC-C : 350Nm
Seaside
4. Air gap - Check any rubbing
All brakes
Note : Fill up where applicable
5. Brake pad and disc (Landside) - Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm)
- Check and clean disc surface
Brake #1 RHS : _____mm, LHS _____mm Disc : _____mm
Note : Fill up where applicable Brake #2 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #3 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #4 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #5 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #6 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #7 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #8 RHS : _____mm, LHS _____mm Disc : _____mm
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
19 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 2 of 4
Description
Location
Observation
Remark
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
All brakes
Good(
) / Not Good(
)
All servolifters
Good(
) / Not Good(
)
- Check pivot pin, linkage, mounting and cover
All brakes
Good(
) / Not Good(
)
- Check limit switch setting and functionality
All brakes
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
6. Brake pad and disc (Seaside) - Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm)
Brake #1 RHS : _____mm, LHS _____mm Disc : _____mm
- Check and clean disc surface Note : Fill up where applicable
Brake #2 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #3 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #4 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #5 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #6 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #7 RHS : _____mm, LHS _____mm Disc : _____mm
Brake #8 RHS : _____mm, LHS _____mm Disc : _____mm 7. Check AWC condition - Check one way bearing and adjusting nut condition Note : Fill up where applicable
8. Servolifter / Thruster - Inspect oil, electrical and mechanical part Note : Fill up where applicable
9. Structure and limit switch
10. Housekeeping
300
- GANTRY GEARBOX INSPECTION
Description
Location
Observation
Remark
1. Gearbox oil - Inspect oil level and oil condition
All gearboxes
Good(
) / Not Good(
)
All gearboxes
Good(
) / Not Good(
)
All gearboxes
Good(
) / Not Good(
)
All gearboxes
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Structure - Inspect mounting bolts tightness and crack Note : Fill up where applicable
3. Bearing - Inspect abnormal sound Note : Fill up where applicable
4. Temperature (40 ~ 60 degree) Note : Fill up where applicable
5. Coupling - Check rubber insert for coupling condition - Check circlips condition Note : Fill up where applicable
6. Housekeeping
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
20 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 3 of 4
310 - GANTRY MOTOR INSPECTION
Description
Location
Observation
Remark
1. Sound inspection - Check any abnormal sound
All motors
Good(
) / Not Good(
)
All motors
Good(
) / Not Good(
)
All motors
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Electrical - Check wire termination at motor termination box
3. Structure - Check cover, mounting and body codition
4. Housekeeping
320 - GANTRY RAIL CLAMP AND ANCHOR PIN INSPECTION
Description
Location
Observation
Remark
1. Rail clamp hydraulic unit - Check oil condition and level - Check piping, any leakage and hose condition
All units
Good(
) / Not Good(
)
All motors
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check wire termination
2. Rail clamp motor - Check any abnormal sound and vibration - Check wire termination
3. Limit switch - Check condition and functionality - Check leakage and mounting condition
4. Structure - Check any leakage and cylinder condition - Check brake shoe / lining condition - Check mounting condition Note : Fill up where applicable
5. Housekeeping
330 - GANTRY ANTI-COLLISION CRANE TO SHIP INSPECTION
Description
Location
Observation
Remark
1. Anti-collision limit switch - Check functionality
Right and left side of boom girder
Good(
) / Not Good(
)
Right and left side of boom girder
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check wire termination and micro switch condition
2. Wire rope - Check wire rope rusty and stringness Note : Fill up where applicable
3. Housekeeping
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
21 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 4 of 4
340
- GANTRY ALARM SYSTEM INSPECTION Description
Location
Observation
Remark
1. Siren - Check siren functionality and condition
All sirens
Good(
) / Not Good(
)
All warning lights
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check wire termination condition
2. Warning light - Check bulb and motor condition - Check lamp cover and mounting condition - Check wire termination condition
3. Housekeeping
350 - GANTRY WHEEL INSPECTION Description
Location
Observation
Remark
1. Wheel - Check wheel bearing condition and abnormal sound
All wheels
Good(
) / Not Good(
)
All wheels
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Structure - Check wheel flange cracks or damages and condition - Check mounting condition
3. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
22 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 1 of 5
360
- BOOM BRAKE INSPECTION
360.1 - SERVICE BRAKE
Description
1. Reserve stroke height (10 mm)
Location
Observation
Remark
Brake #1 (Height : _________ mm)
Good(
) / Not Good(
)
Brake #1 (Torque : ________________ Nm)
Good(
) / Not Good(
)
Service brake
Good(
) / Not Good(
)
- Inspect stroke indicator setting and manual release . - Inspect setting and mechanical component Note : IMPSA-A : ≥ 1890Nm, NOELL/MITSUI/ZPMC-A: ≥ 14850 Nm, IMPSA-B : >7200Nm, ZPMC-B : >5940Nm, ZPMC-C: >6000Nm
3. Air gap - Check any rubbing
Brake pad RHS : ________mm
Good(
) / Not Good(
)
- Check and clean disc surface
Brake pad LHS : ________mm
Good(
) / Not Good(
)
- Inspect pad and disc (Pad : ≥ 5 mm, Disc : ≥ 27 mm)
Brake disc
Good(
) / Not Good(
)
Service brake
Good(
) / Not Good(
)
Service brake
Good(
) / Not Good(
)
Service brake
Good(
) / Not Good(
)
Good(
) / Not Good(
)
a. Brake manual release
Good(
) / Not Good(
)
b. Brake release
Good(
) / Not Good(
)
c. Brake pad wear
Good(
) / Not Good(
)
4. Brake pad and disc
: ________mm
ZPMC (Pad : >3.0 mm, Disc : >1.0mm wear on each side )
5. Check AWC condition - Check one way bearing and adjusting nut condition
6. Check wedge and shackle kit
7. Servolifter / Thruster - Inspect oil, electrical and mechanical part
8. Structure - Check pivot pin, linkage and mounting
9. Limit Switch - Check setting and functionality
360.2 - EMERGENCY BRAKE
Description
Location
Observation
Remark
1. Hydraulic power pack - Check oil condition and working pressure (150-180 bar)
Hydraulic oil tank
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Good(
) / Not Good(
)
2. Hydraulic cylinder and block - Check leakage
3. Proximity Sensor & Motor - Check setting and functionality
All location
- Check electrical and mechanical parts
Brake #1 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
- Inspect pad and disc (Pad : ≥ 8 mm, Disc : ≥ 28 mm)
Brake #1 LHS : ______mm
Good(
) / Not Good(
)
- Check and clean disc surface
Brake #2 RHS : ______mm
Good(
) / Not Good(
)
Brake #2 LHS : ______mm
Good(
) / Not Good(
)
Brake #3 RHS : ______mm , Disc : ______mm
Good(
) / Not Good(
)
Brake #3 LHS : ______mm
Good(
) / Not Good(
)
Brake #4 RHS : ______mm
Good(
) / Not Good(
)
Brake #4 LHS : ______mm
Good(
) / Not Good(
)
Done(
) / Not Done(
)
4. Brake pad and disc
Note : Fill up where applicable
5. Housekeeping
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
23 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 2 of 5
370 - BOOM GEARBOX / REDUCER
Description
Location
Observation
Remark
1. Gearbox oil - Inspect oil level and oil condition
Gearbox #1
Good(
) / Not Good(
)
Gearbox #1
Good(
) / Not Good(
)
Gearbox #1
Good(
) / Not Good(
)
Gearbox #1 : _________degree
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Structure - Inspect mounting bolts tightness and crack
3. Bearing - Inspect abnormal sound
4. Temperature (40 ~ 60 degree)
5. Housekeeping
380 - BOOM MOTOR
Description
1. Sound inspection
Location
Observation
Remark
Boom motor
Good(
) / Not Good(
)
Boom motor
Good(
) / Not Good(
)
Boom emergency motor
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Visual check - Check structure and wire termination
3. Emergency Motor - Check coupling condition - Check limit switch working condition
4. Housekeeping
390 - BOOM WIRE ROPE INSPECTION
Description
Location
Observation
Remark
1. Visual check Wire rope drum
Good(
) / Not Good(
- Broken strands (<18 wires)
Boom tip
Good(
) / Not Good(
)
- Diameter : IMPSA-A : >28.8mm, IMPSA-B : >34.2mm,
A-Frame
Good(
) / Not Good(
)
- Check loosed nut and condition
Length #1
Good(
) / Not Good(
)
Note : Fill up where applicable
Length #2
Good(
) / Not Good(
)
Wire rope
Good(
) / Not Good(
)
All plates
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check broken strands, deformation and kinks
)
ZPMC-A/C : 36mm~33.4mm, ZPMC-B : 32.4mm NOELL/MITSUI : 30mm~2 7.9mm
2. Clips and turnbuckles
3. Check for lubrication - Check rusty
4. Support plate - Check condition
5. Housekeeping
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
24 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 3 of 5
400 - BOOM WIRE ROPE DRUM INSPECTION
Description
Location
Observation
Remark
1. Check wire rope anchor
All drums
Good(
) / Not Good(
)
2. Check bearing any abnormal noise
All drums
Good(
) / Not Good(
)
3. Check groove surface condition
All drums
Good(
) / Not Good(
)
4. Check structure and mounting
All drums
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
5. Housekeeping
410 - BOOM SHEAVE AND BEARING INSPECTION
Description
1. Check groove condition any damaged or rope trace mark
2. Check locking / keeper plate condition
3. Check bearing condition
4. Structure and mounting - Check condition and bolt tightness
5. Housekeeping
Location
Observation
Remark
Boom tip
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
Boom tip
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
420 - BOOM MOTOR AND GEARBOX COUPLING INSPECTION
Description
1. Check abnormal sound
Location
Observation
Remark
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Check coupling cover Note : Fill up where applicable
3. Check rubber insert condition Note : Fill up where applicable
4. Structure and mounting - Check bolt tightness and condition
5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
25 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST BOOM : Page 4 of 5
430
- BOOM LIMIT SWITCH INSPECTION
Description
Location
Observation
Remark
1. Cable / conduit - Check cable condition, insulation and cable lug
A-Frame
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Limit switch - Check positioning, rusty, functionality and mounting
3. Striker - Check condition
4. Housekeeping
440
- BOOM CAM SWITCH INSPECTION
Description
Location
Observation
Remark
1. Cable termination - Check cable damage and breakage at cable lugs
Boom drum
Good(
) / Not Good(
)
All switches
Good(
) / Not Good(
)
All couplings
Good(
) / Not Good(
)
Boom drum
Good(
) / Not Good(
)
Boom drum
Good(
) / Not Good(
)
Boom drum
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Cam switch functionality - Function test
3. Cam switch coupling tightness - Check bolt tightness
4. Check 3-way gear condition Note : Fill up where applicable
5. Driven belt / driven chain - Check belting condition and any crack Note : Fill up where applicable
6. Driven pulley - Check pulley mounting, side guide, wear and crack Note : Fill up where applicable
7. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
26 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM : Page 5 of 5
450 - BOOM LATCH INSPECTION
Description
Location
Observation
Remark
1. Servolifter - Check oil condition and any leakage - Check linkage split-pin and conduit condition
A-Frame
Good(
) / Not Good(
)
All limit switches
Good(
) / Not Good(
)
Boom latch
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check rubber bumper Note : Fill up where applicable
2. Limit Switch - Check condition and functionality Note : Fill up where applicable
3. Structure and mounting - Check condition and bolt tightness Note : Fill up where applicable
4. Power pack - Check oil condition and any leakage Note : Fill up where applicable
5. Plunger - Check plunger and spring condition Note : Fill up where applicable
6. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
27 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 1 of 3
460 - EMERGENCY STOP SYSTEM INSPECTION
Description
1. Machinery house - Check functionality and condition Note : Fill up where applicable
Location
Observation
Remark
Electrical room (inside)
Good(
) / Not Good(
)
PLC panel
Good(
) / Not Good(
)
DC bus shift cub
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
Trolley / hoist emergency station
Good(
) / Not Good(
)
- Check functionality and condition
Trolley house inside
Good(
) / Not Good(
)
Note : Fill up where applicable
Trolley house panel
Good(
) / Not Good(
)
2. Trolley
3. Boom
Boom emergency station
Good(
) / Not Good(
)
- Check functionality and condition
Boom top outside
Good(
) / Not Good(
)
Note : Fill up where applicable
Boom top inside
Good(
) / Not Good(
)
Boom girder end
Good(
) / Not Good(
)
4. Cabin - Check functionality and condition Note : Fill up where applicable
5. Portal - Check functionality and condition Note : Fill up where applicable
6. Others - Check functionality and condition Note : Fill up where applicable
Checker cabin panel
Good(
) / Not Good(
)
Cabin operator console
Good(
) / Not Good(
)
Boom opeartor cabin
Good(
) / Not Good(
)
Portal landside left
Good(
) / Not Good(
)
Portal landside right
Good(
) / Not Good(
)
Portal seaside left
Good(
) / Not Good(
)
Portal seaside right
Good(
) / Not Good(
)
Gantry operation station
Good(
) / Not Good(
)
High voltage cable reel station
Good(
) / Not Good(
)
TLS station
Good(
) / Not Good(
)
Done(
) / Not Done(
)
7. Housekeeping
All location
470 - FLOODLIGHT INSPECTION
Description
1. Boom floodlight
Location
Observation
Remark
Boom tip
Good(
) / Not Good(
)
- Check functionality and condition
Boom joint
Good(
) / Not Good(
)
- Check wire termination
Boom center cross beam
Good(
) / Not Good(
)
Boom center
Good(
) / Not Good(
)
2. Trolley floodlight - Check functionality and condition
Trolley platform
Good(
) / Not Good(
)
Operator cabin
Good(
) / Not Good(
)
- Check wire termination Note : Fill up where applicable
Seaside
Good(
) / Not Good(
)
- Check functionality and condition
Right hand side
Good(
) / Not Good(
)
- Check wire termination
Left hand side
Good(
) / Not Good(
)
Landside RHS
Good(
) / Not Good(
)
Landside LHS
Good(
) / Not Good(
)
3. Machinery house
Note : Fill up where applicable
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
28 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 2 of 3
Description
Location
Observation
Remark
4. Backreach - Check functionality and condition - Check wire termination
Backreach
Good(
) / Not Good(
)
Multi-functional platform
Good(
) / Not Good(
)
Note : Fill up where applicable
5. Portal beam - Check functionality and condition
Right hand side
Good(
) / Not Good(
)
- Check wire termination
Left hand side
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
6. Housekeeping
480 - OPERATOR CABIN INSPECTION
Description
Location
Observation
Remark
1. Master controller / joystick - Check functionality and condition
Right side consol
Good(
) / Not Good(
)
- Check wire termination
Left side consol
Good(
) / Not Good(
)
2. Electrical system
Wall fan
Good(
) / Not Good(
)
- Check functionality and condition
Cabin lamp
Good(
) / Not Good(
)
- Check wire termination
Power socket
Good(
) / Not Good(
)
- Check power supply functionality
Access gate limit switch
Good(
) / Not Good(
)
Electrical panel
Good(
) / Not Good(
)
- Check functionality and condition
Right side consol
Good(
) / Not Good(
)
- Check wire termination
Left side consol
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
3. Selector switch and push button
4. Indicator light - Check functionality and condition - Check wire termination
5. Consol - Check wire termination and condition
Right side consol
Good(
) / Not Good(
)
Left side consol
Good(
) / Not Good(
)
Siren
Good(
) / Not Good(
)
6. Foot siren - Check functionality and condition - Check wire termination
Cabin door
Good(
) / Not Good(
)
- Check structure condition
Access gate
Good(
) / Not Good(
)
- Check wind screen/ glass condition
All bushings
Good(
) / Not Good(
)
Handrail
Good(
) / Not Good(
)
Access ladder
Good(
) / Not Good(
)
Support beam
Good(
) / Not Good(
)
Platform
Good(
) / Not Good(
)
Amplifier and speaker
Good(
) / Not Good(
)
Operator seat
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
7. Structure
8. Public access (PA) system - Check functionality and condition - Check wire termination
9. Operator seat - Check functionality and condition
10. Housekeeping
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
29 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 3 of 3
490 - AIR-CONDITIONER INSPECTION
Description
Location
Observation
Remark
1. Compressor - Check structure and condition
Control room
Good(
) / Not Good(
)
- Check wire termination and functionality
Operator cabin
Good(
) / Not Good(
)
- Check gas quantity and any leakage
Checker cabin
Good(
) / Not Good(
)
Note : Fill up where applicable
2. Indoor unit - Check structure and condition
Control room
Good(
) / Not Good(
)
- Check wire termination and functionality
Operator cabin
Good(
) / Not Good(
)
Checker cabin
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
3. Tubing and fitting - Check tube condition and any leakage
4. Mechanical part - Check blower motor mounting condition - Check belting condition - Check cleanliness
5. Housekeeping
500
- SOFTWARE AND PROGRAM MONITORING
Please see attachment (if any)
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
30 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
510 - MAIN HOIST SYSTEM GREASING
Description
Location
Observation
Remark
1. Main hoist hoist system - Pump-in new grease into greasing point Note : Fill up where applicable
2. Housekeeping Housekeeping
Headblock sheave
Done(
) / Not Done(
)
Headblock twistlock
Done(
) / Not Done(
)
Backreach-main Backreach -main hoist sheave
Done(
) / Not Done(
)
Trolley platform-mai n hoist sheave
Done(
) / Not Done(
)
Main hoist drum sheave
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
520 - TROLLEY SYSTEM GREASING
Description
Location
Observation
Remark
1. Trolley Trolley system
- Pump-in new grease into greasing point Note : Fill up where applicable
2. Housekeeping Housekeeping
Trolley sheave
Done(
) / Not Done(
)
Trolley floating shaft
Done(
) / Not Done(
)
Trolley plumber block
Done(
) / Not Done(
)
Catenary wheel
Done(
) / Not Done(
)
Catenary sheave
Done(
) / Not Done(
)
Catenary McGill guide roller
Done(
) / Not Done(
)
Backreach-catenary Backreach -catenary sheave
Done(
) / Not Done(
)
Backreach rope tensioner bearing
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
530 - BOOM SYSTEM GREASING
Description
Location
Observation
Remark
1. Boom Boom system - Pump-in new grease into greasing point
Boom drum
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
2. Housekeeping Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
31 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page Page 1 of 3
540
- PASSENGER LIFT INSPECTION
Description
Location
Observation
Remark
1. Guide rail All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
Top of cabin
Good(
) / Not Good(
)
All brakes
Good(
) / Not Good(
)
All floors
Good(
) / Not Good(
)
All push buttons
Good(
) / Not Good(
)
Power cable
Good(
) / Not Good(
)
Carrier
Good(
) / Not Good(
)
Inside carrier
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
- Check buffer spring and rail condition - Check mounting condition
2. Gear - Check rack and pinion gear condition
3. Reduction gear box - Check gearbox condition - Check mounting condition
4. Motor - Check casing and mounting condition
5. Brake - Check functionality and brake condition
6. Cabin level - Check setting on each floor level
7. Push button - Check functionality and condition
8. Cable - Check cable insulation and condition - Check protection rubber and mounting condition
9. Carrier structure - Check door and roof door condition - Check ladder condition
10. Intercomm - Check condition and functionality
11. Housekeeping
550 550 - FIRE ALARM SYSTEM INSPECTION
Description
Location
Observation
Remark
1. Electrical Electrical part - Check AC power LED light up
Machinery house
- Determine standby battery condition condition ( 25.5 25.5 ≤ x ≤ 26.6 Vdc )
- Zone 1
Good(
) / Not Good(
- Check any alarm LED light up from panel
- Zone 2
Good(
) / Not Good(
)
- Zone 3
Good(
) / Not Good(
)
- Fire, Fault, Off, Extinguisher release, Walk test, External acoustic alarm off, CPU fault, Power supply fault. - Any fault message on the display (Stated the fault message) Note : Fill up where applicable
)
- Zone 4
Good(
) / Not Good(
)
- Main
Good(
) / Not Good(
)
- Charger
Good(
) / Not Good(
)
- Evacuate
Good(
) / Not Good(
)
Good(
) / Not Good(
)
2. Mechanical Part - Visual Check for cylinder pressure gauge reading (±170 bar for 225 bar system) - Examine cylinder valve and hoses for sign of damage, wear or leakage - Inspect all piping & nozzles for any sign damage & leakage Note : Fill up where applicable
Good(
) / Not Good(
)
Good(
) / Not Good(
)
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
32 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 2 of 3
560 - MAINTENANCE HOIST CRANE INSPECTION
Description
Location
Observation
Remark
1. Limit switch and functional test - Hoist up stop
Machinery house
Good(
) / Not Good(
- Hoist up slow down
Machinery house
Good(
) / Not Good(
) )
- Hoist down stop
Machinery house
Good(
) / Not Good(
)
- Trolley forward stop
Machinery house
Good(
) / Not Good(
)
- Trolley forward slow down
Machinery house
Good(
) / Not Good(
)
- Trolley backward stop
Machinery house
Good(
) / Not Good(
)
- Trolley backward slow down
Machinery house
Good(
) / Not Good(
)
- Gantry right stop
Machinery house
Good(
) / Not Good(
)
- Gantry right slow down
Machinery house
Good(
) / Not Good(
)
- Gantry left stop
Machinery house
Good(
) / Not Good(
)
- Gantry left slow down
Machinery house
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
Rubber buffer
Good(
) / Not Good(
)
Hook block
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
Electrical box
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Control console - Check functionality and condition - Check structure
3. Structure - Check structure condition - Check hook and latch condition
4. Wire rope and turn buckle - Check loosed nut and wire rope condition - Check any rusty
5. Electrical part - Check wire termination and contactor condition
6. Housekeeping
570
- AIR COMPRESSOR INSPECTION
Description
Location
Observation
Remark
1. Compressor - Check oil level sufficient, air filter, V-belt, pressure gauge,
Machinery house
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
Machinery house
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
safety valve, piping and mounting condition - Check any abnormal sound or vibration
2. Pressure Switch - Check pressure setting Note : Cut in: 9.9 kg/cm2 & Cut out: 8.0 kg/cm2 - Adjusting screw locknut and check wire termination
3. Motor - Check mounting and any abnormal sound
4. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
33 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
AUXILARY : Page 3 of 3
580
- QC CHECKER CABIN INSPECTION
Description
Location
Observation
Remark
1. Socket & power supply - Check mounting and condition
2. Check lighting condition and functionality
All location
Good(
) / Not Good(
)
Cabin ceiling
Good(
) / Not Good(
)
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
3. Intercomm - Check condition and functionality
4. Structure - Check mounting and condition - Check door and glass
5. Housekeeping
General Remark :
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
34 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
BOOM: Page 1 of 1
590
- BOOM FORESTAY INSPECTION
Description
Location
Observation
Remark
1. Bushing - Check abnormal sound and vibration
All location
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
All supports
Good(
) / Not Good(
)
A-Frame
Good(
) / Not Good(
)
All location
Done(
) / Not Done(
)
2. Structure and mounting - Check condition and mounting
3. Rest support - Check forestay rest support condition
4. Boom buffer - Check condition and mounting
5. Housekeeping
600
- BOOM SHEAVE INSPECTION
Description
Location
Observation
Remark
1. Check bearing condition
All sheaves
Good(
) / Not Good(
)
2. Check grove condition
All sheaves
Good(
) / Not Good(
)
All sheaves
Good(
) / Not Good(
)
All sheaves
Done(
) / Not Done(
)
3. Structure - Check mounting and condition
4. Housekeeping
610
- BOOM CABIN INSPECTION
Description
Location
Observation
Remark
1. Indicator bulb - Check condition and functionality
2. Check lighting condition and functionality
All indicators bulbs
Good(
) / Not Good(
)
Cabin ceiling
Good(
) / Not Good(
)
All location
Good(
) / Not Good(
)
Good(
) / Not Good(
)
Done(
) / Not Done(
)
3. Structure - Check mounting and condition - Check door and glass
4. Intercomm - Check condition and functionality
5. Housekeeping
General Remark :
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
35 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
620
- GANTRY SYSTEM GREASING
Description
Location
Observation
Remark
1. Gantry system - Pump-in new grease into greasing point
2. Housekeeping
630
All boggies
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
- BOOM SYSTEM GREASING
Description
Location
Observation
Remark
1. Boom system - Pump-in new grease into greasing point
2. Housekeeping
All boom sheaves
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
640 - MAIN HOIST WIRE ROPE LUBRICATION
Description
Location
Observation
Remark
1. Main hoist wire rope - Check condition and lubricate wire rope
2. Housekeeping
All main hoist wire ropes
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
650 - TROLLEY WIRE ROPE LUBRICATION
Description
Location
Observation
Remark
1. Trolley wire rope - Check condition and lubricate wire rope
All trolley wire ropes
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
2. Housekeeping
660 - BOOM WIRE ROPE LUBRICATION
Description
Location
Observation
Remark
1. Boom wire rope - Check condition and lubricate wire rope
2. Housekeeping
All boom wire ropes
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
670 - CATERNARY WIRE ROPE LUBRICATION
Description
Location
Observation
Remark
1. Catenary wire rope - Check condition and lubricate wire rope
All caternary wire ropes
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
2. Housekeeping
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
36 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GANTRY : Page 1 of 1
680
- MAIN CABLE REEL INSPECTION
Description
Location
Observation
Remark
1. Motor - Check mounting and condition
Main cable reel motor
Good(
) / Not Good(
)
Main power cable
Good(
) / Not Good(
)
All mounting
Good(
) / Not Good(
)
Good(
) / Not Good(
)
2. Main cable - Check cable condition
3. Structure - Check mounting and condition
4. Slip ring - Check slip rings condition
5. Gearbox - Check gearbox oil condition
Good(
) / Not Good(
)
- Check mounting and condition
Good(
) / Not Good(
)
- Check any abnormal sound
Good(
) / Not Good(
)
Done(
) / Not Done(
)
6. Housekeeping
General Remark :
All location
SUPPORTING DOCUMENT
Document No.
FM-M&R-QC002-000
Revision No.
000
Effective Date
15-Apr-10
Page
37 of 38
TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST
GREASE : Page 1 of 1
690 - BOOM BACKSTAY GREASING
Description
Location
Observation
Remark
1. Boom backstay - Pump-in new grease into greasing point
All greasing points
Done(
) / Not Done(
)
All location
Done(
) / Not Done(
)
Note : Fill up where applicable
2. Housekeeping
700
- KBT COUPLING GREASING
Description
Location
Observation
Remark
1. KBT coupling - Pump-in new grease into greasing point
Done(
) / Not Done(
)
Done(
) / Not Done(
)
Note : Fill up where applicable Please see attachment (No. :
2. Housekeeping
General Remark :
)
All location
