NATURE OF SERVICING AND MAINTENANCE TO BE CHECKED

PERIODICALLY ONCE EVERY 3 MONTHS

1.0 PERIODICAL AND PREVENTIVE MAINTENANCE: ONCE EVERY 4 MONTHS

1.1 BRIDGE RAILS (L.T & C.T) WITH CLAMPING SYSTEM:

1.1.1 Check the fastening of crane rails and clamps and rectify, if required.

1.1.2 Check rail wear on top and sides and report any abnormality. 1.2.0

GIRDERS ON BUILDING & CRANE

1.2.1 Check the foundation bolts, splices, loose bolts or missing bolts/rivets and for cracked
welds and Splices and rectify wherever required.

1.3.0 END CARRIAGE (END TRUCKS):

1.3.1 Check the overall condition of end carriage and report any cracks in the welds or abnormal
wear of rail and wheels. Rectify wherever required.

1.3.2 Rail sweeps to be checked and fixed properly, if needed.

1.3.3 WHEELS: Check for the non-uniform wear, correct the Wheel axle for proper alignment.

1.3.4 BUMPERS: To be checked and rectified if there is any defect.

1.3.5 End carriages and the bridge girder fasteners are to be checked and properly tightened

1.3.6 Attachment to end carriages – loose or missing rivets or bolts or broken/cracked welds to be
Checked and rectified.

1.4.0 DRIVE SYSTEM (L.T & C.T):

1.4.1 Check the tightness of the bolts of the motor base, Plummer blocks, and its supports, brake
unit Supports, gearbox supports, L.T & C.T. Shaft connecting the wheels etc., and rectify, if
required.

1.4.2 Check the coupling condition and tightness of the key.

1.4.3 Check the gearbox for leakage of oil, loose bolts or cracks in the gearbox, observe the
noise level and report before rectification.

1.5.0 HOIST DRIVE SYSTEM MAIN/MICRO/AUXILIARY WHEREVER APPLICABLE:

1.5.1 Check the free rotation of the hook/Rotating hook block where applicable

1.5.2 Check the free movement of snatch block

1.5.4 Check tightness of fasteners at the end fixing of wire rope on rope drum and also rope
drum fixing system.
1.5.5 Check the freeness of equalizer pulley system.

1.5.6 Check all the fasteners for proper fixing of motor, gearboxes, brake units etc.
1.5.7 i) Check the coupling condition.
ii) Check the tightness of the key.

1.5.8 Check the gearbox for leakage of oil, loose bolts, or cracks in the box, observe the
noise level and report before carrying out repair works.

1.6.0 BRAKE UNITS: (FOR L.T & C.T AND HOIST MOTIONS):

1.6.1 Brake shoe connecting linkages shall be checked and to be adjusted if required.

1.6.2 Adjust the spring tension for proper braking condition.

1.6.3 Check the condition for brake liner and replace, if require.

1.6.4 In electro-magnetic (E.M) type of brakes, ensure that the plunger inside the core shall
be atleast 1/3 of the core depth for proper operation.
1.6.5 Check the brake coil guide assembly (EM Brake) for proper plunger operation (for all
motions).
1.6.6 In case of thruster brakes, check for oil condition and level and rectify, if required.
1.6.7 Brake currents are to be measured and recorded wherever the brakes are adjusted.
(Before and after the adjustments)
1.7.0 LUBRICATION
1.7.1 GEARBOXES (FOR L.T., C.T. AND HOIST MOTIONS):
Check the condition of oil and replace if required.
1.7.2 CENTRALISED LUBRICATION SYSTEM
All grease nipple and oil points shall be packed with lubricant.
1.7.3 Lubrication of all mechanical components (viz., hook, pulleys, rope, brake, gears,
gearboxes, plummer blocks, wheels and axels, coupling, bushes etc.,) topping up or
replacing lubrication oil wherever required. (Galvanished hard core wire ropes
should not be lubricated).
1.7.4 If the pipelines of the centralized lubrication system are blocked, it shall be repaired
before the application of lubricants.
1.8.0 LIMIT SWITCHES; (FOR L.T., C.T. AND HOIST MOTIONS):
1.8.1 Check all operation of all limit switches for L.T., C.T. and Hoist (upper & lower)
and also for gravity limit switch and rotary limit switches.
1.8.2 Check the rotary limit switch cam system.
1.9.0 ELECTRICAL SYSTEMS

1.9.1 Check the free movement for guide, guide rail /rollers, push rod, connecting chains,
clamping of all trailing cable units and rectify the defects, if any.
1.9.2.0 INSPECTION OF INCOMING PANEL AND CONTROL PANELS;
1.9.2.1 Tighten all terminals inside the panel.
1.9.2.2 Check the correct fuse ratings.
1.9.2.3 Check the over load relay settings (set over load relay to full load current of the motor)
1.9.2.4 Check the chattering and sluggish operation of power contactors and ISR relays.
1.9.2.5 Check the earthing of the motors for proper tightness and contact.
1.9.2.6 Ensure all panel door bolts are fixed.
1.9.2.7 Check and tighten all electrical connections in the motors.
1.9.2.8 Clean the terminal blocks of motors, brakes, junction boxes, limit switches etc.,
1.9.2.9 Check the limit switches functioning for all motions.
1.9.2.10 Check the brake coil operation for non-humming condition and proper closing.
1.9.2.11 Check the brake coil resistance.
1.9.2.12 Roller actuation of the limit switches shall be checked manually.
1.9.2.13 Check all electrical connections of the pendant.
1.9.2.14 Check all push button’s actuation.
1.9.2.15 Check for proper operation for all motions of pendant push buttons.
1.10.0 CLEANING
1.10.1 After all the works are completed, remove tools, tackles, wastes, oilcan, grease etc.,
1.10.2 Secure all covers after maintenance.
1.10.3 Clean the crane, L.T., Girder, walkways etc thoroughly.
2.0 ANNUAL SERVICING AND LOAD TESTING ONCE IN
A YEAR
In addition to the work mentioned under periodical preventive maintenance, the
following works can also to be carried out for Annual Servicing and Load testing
for each crane if the time frame falls within the period technicians are on site.
2.1.0 L.T. & C.T. DRIVE SYSTEMS
2.1.1 All couplings are to be removed, checked and refitted.
2.1.3 All gearboxes have to be opened and inspected thoroughly, Oil seals/gaskets etc.,
shall be changed, if required.
2.1.4 Alignment of all drive chains shall be checked and corrected, if required.
2.2.0 HOIST DRIVE SYSTEMS (AUX. AND MAIN):
2.2.1 All couplings are to be removed, checked and refitted.
2.2.2 All plummer block covers are to be removed, bearings are to be checked and refitted.
2.2.3 All gearboxes have to be opened and inspected thoroughly. Oil seals/gaskets etc.,
shall be changed if required.
2.2.4 Alignment of all drive chains including rope drum shall be checked and corrected,
if required.
2.3.0 INSPECTION OF WIRE ROPES
2.3.1 Check the hoist rope reeving, rope wear, twist, kink, break, interference with any
other member etc., while in operation. New rope is to be laid, if the old wire rope is
required to be replaced.
2.3.2 Check the condition of hoist drum (rope drum) bolts tightness, bearing condition,
grooves and ridges. Replace with new ones, if required.
2.3.3 Check the general condition of bull gear and connecting gear train. Replace with
new ones, if required.
2.4.0 BRIDGE RAILS (L.T. & C.T.)
2.4.1 Check and align the rails, if required.
2.4.2 Check the end stoppers and rectify, if required.
2.5.0 BRIDGE GIRDERS
2.5.1 Check the welding condition, rivet or bolted joints throughout the length of the
girder and rectify, if required.
2.5.2 Check the splice joints for any abnormality and rectify, if required.
2.5.3 Check walkway plates and hand rails and rectify, if found defective.
2.6.0 ELECTRICAL SYSTEMS:

2.6.1 Inspection of Incoming panel and Control Panels:

2.6.6 Check the electrical motor bearing condition and replace if required. 2.6.7
Check the condition of fan blades of motors and tighten all the fasteners.

2.6.8 Measure insulation resistance value of all cables including pendant cables.
2.6.9 Check the condition of electrical trailing cables, L.T.C.T., down shop leads etc., and
rectify, if required.
2.6.10 Check the cable glands for proper condition and replace, if necessary.
2.6.11 Check loose connection inside the limit switches and tighten them, if necessary.
2.7 LOAD TESTING
2.7.1 After carrying out the annual servicing and maintenance of the crane and satisfactory
completion of the written report, each crane shall be load tested in the presence of
the client. Mobilization of dead weights for load testing from facility to facility will
be the client’s scope. The Client will supply the dead weights required for the load
testing and trailers for transporting dead weights from facility to facility.

2.7.2 Any tools and accessories required to carry out the load test as given in the following
list have to be brought by the client for each crane.
Note: all the instruments used should have been calibrated before use and the
certificate to this effect should be shown to the Contractor, if demanded.
2.7.4 The currents of all the motors and brakes as well as the speeds of LT, CT and Hoist
motions are to be measured and recorded in the prescribed format.