01+ +QC+Preventive+Maintenance+Checklist+(Drafted+Q34 Q44)(1)

Document No. Revision No. Effective Date SUPPORTING DOCUMENT TITLE : QUAY CRANE PREVENTIVE MAINTENANCE CHECKLIST Page

20

- MAIN HOIST GEARBOX / REDUCER Description Location Observation

1. Gearbox oil - Inspect oil level and oil condition Note : Fill up where applicable 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 Gearbox #2 Gearbox #1 : _________degree Gearbox #2 : _________degree All location Good( Good( Good( Good( Done( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) ) ) Gearbox #1 Gearbox #2 Good( Good( ) / Not Good( ) / Not Good( ) ) Gearbox #1 Gearbox #2 Good( Good( ) / Not Good( ) / Not Good( ) )

30

- MAIN HOIST DRIVE & BLOWER MOTOR Description Location Motor #1 Motor #2 Motor #1 Motor #2 Good( Good( Good( Good( Observation ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) )

1. Sound inspection Note : Fill up where applicable 2. Check heater Note : For DC motor only 3. Visual check - Check coupling motor & gear box (Bush Coupling) - Check terminations - Check mounting bolts and frame Note : Fill up where applicable 4. Check blower motor cond. - Check rotation - Check running cond - Measure motor demands 5. Emergency Motor - Check coupling condition & chain link - Check limit switch working condition 6. Air Filter - Check clealiness

Motor #1 Motor #2 Motor #3 Motor #4 Motor #1 Motor #2 Motor #3 Motor #4

Good( Good( Good( Good( Good( Good( Good( Good(

) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good(

) ) ) ) ) ) ) )

Motor #1 Motor #2 Motor #1 Motor #2 Motor #3 Motor #4

Good( Good( Good( Good( Good( Good(

) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good(

) ) ) ) ) )

7. Housekeeping

All location

Done(

) / Not Done(

)


40

- MAIN HOIST WIRE ROPE INSPECTION Description Location Observation

1. Visual check - Check broken strands, deformation and kinks - Diameter (NOELL/ZPMC-A : 26.2mm~28.0mm) - Diameter (IMPSA : 26.7mm~28.5mm) - Diameter (MITSUI : 26.2mm~23.3mm) - Diameter (ZPMC-C : 32.00mm~29.76mm) - Broken strands (20% from 30mm, Pad >3mm - Check and clean disc surface Note : Fill up where applicable All brakes Brake #1 RHS : ______mm , Disc : ______mm Brake #1 LHS : ______mm Brake #2 RHS : ______mm , Disc : ______mm Brake #3 RHS : ______mm , Disc : ______mm Brake #3 LHS : ______mm Brake #4 RHS : ______mm , Disc : ______mm Brake #4 LHS : ______mm 5. Check AWC condition - Check one way bearing and adjusting nut condition Note : Fill up where applicable Brake #1 Brake #2 Brake #3 Brake #4 6. Check wedge and shackle kit Note : Fill up where applicable Brake #1 Brake #2 Brake #3 Brake #4 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 a. Brake manual release b. Brake release c. Brake pad wear All location Good( Good( Good( Good( Done( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) ) ) All servolifters Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) )

ZPMC(Pad : 3 mm, Disc : 1.0mm wear on each side) Brake #2 LHS : ______mm

General Remark :


160

- TROLLEY GEARBOX INSPECTION Description Location Gearbox #1 Gearbox #2 Gearbox #3 Gearbox #4 Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Done( Observation ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) )

1. Gearbox oil - Inspect oil level and oil condition Note : Fill up where applicable

2. Structure - Inspect mounting bolts tightness and crack Note : Fill up where applicable

Gearbox #1 Gearbox #2 Gearbox #3 Gearbox #4

3. Bearing - Inspect abnormal sound Note : Fill up where applicable


4. Temperature (40 ~ 60 degree) Note : Fill up where applicable

Gearbox #1 : _________degree Gearbox #2 : _________degree Gearbox #3 : _________degree Gearbox #4 : _________degree

5. Housekeeping

All location

170

- TROLLEY MOTOR INSPECTION Description Location Motor #1 Motor #2 Motor #3 Motor #4 Good( Good( Good( Good( Good( Good( Observation ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) )

1. Sound inspection Note : Fill up where applicable

2. Check heater condition Note : For DC motor only Note : Fill up where applicable 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 Motor #1 Motor #2 Good( Good( ) / Not Good( ) / Not Good( ) ) Motor #1 Motor #2 Motor #3 Motor #4 Motor #1 Motor #2 Good( Good( Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) ) Motor #1 Motor #2


Description 6. Carbon brush and holder - Check length and condition Note : For DC motor only

Location Motor #1 - Top (3 pcs) Motor #1 - Bottom (3 pcs) Motor #1 - Right (3 pcs) Motor #1 - Left (3 pcs) Motor #2 - Top (3 pcs) Motor #2 - Bottom (3 pcs) Motor #2 - Right (3 pcs) Motor #2 - Left (3 pcs) Good( Good( Good( Good( Good( Good( Good( Good( Done(

Observation ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) ) ) ) ) ) )

7. Housekeeping

All location

180

- TROLLEY WIRE ROPE INSPECTION Description Location Observation

1. Visual check - Check broken strands, deformation and kinks - Diameter (2 6.2mm~mm) - Broken strands ( 207Nm, ZPMC-B : >320Nm, ZPMC-C : 350Nm

All brakes

Good(

) / Not Good(

)

#5 : ______ mm) #6 : ______ mm) #7 : ______ mm) #8 : ______ mm)

Good( Good( Good( Good(

) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good(

) ) ) )

#5 : ______ mm) #6 : ______ mm) #7 : ______ mm) #8 : ______ mm)



) ) ) )

Lanside Torque : #1 : ______ Nm Torque : #2 : ______ Nm Torque : #3 : ______ Nm Torque : #4 : ______ Nm Seaside Torque : #1 : ______ Nm Torque : #2 : ______ Nm Torque : #3 : ______ Nm Torque : #4 : ______ Nm #5 : ______ Nm) #6 : ______ Nm) #7 : ______ Nm) #8 : ______ Nm) Good( Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) #5 : ______ Nm) #6 : ______ Nm) #7 : ______ Nm) #8 : ______ Nm) Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) )

4. Air gap - Check any rubbing 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 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 Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) ) ) ) ) ) ) ) ) ) Brake #1 RHS : _____mm, LHS _____mm Disc : _____mm Good( Good( ) / Not Good( ) / Not Good( ) ) All brakes


Description

Location

Observation

6. Brake pad and disc (Seaside) - Inspect pad and disc (Pad : 5 mm, Disc : 27 mm) - Check and clean disc surface Note : Fill up where applicable

Brake #1 RHS : _____mm, LHS _____mm Disc : _____mm 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

Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good(

) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good(

) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) )

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 - Check pivot pin, linkage, mounting and cover - Check limit switch setting and functionality 10. Housekeeping All brakes All brakes All location Good( Good( Done( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) All servolifters Good( ) / Not Good( ) All brakes

300

- GANTRY GEARBOX INSPECTION Description Location Observation

1. Gearbox oil - Inspect oil level and oil condition 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 All couplings Good( ) / Not Good( ) All gearboxes Good( ) / Not Good( ) All gearboxes Good( ) / Not Good( ) All gearboxes Good( ) / Not Good( ) All gearboxes Good( ) / Not Good( )

6. Housekeeping

All location

Done(

) / Not Done(

)


310

- GANTRY MOTOR INSPECTION Description Location Observation

1. Sound inspection - Check any abnormal sound 2. Electrical - Check wire termination at motor termination box 3. Structure - Check cover, mounting and body codition 4. Housekeeping All motors All location Good( Done( ) / Not Good( ) / Not Done( ) ) All motors Good( ) / Not Good( ) All motors Good( ) / Not Good( )

320

- GANTRY RAIL CLAMP AND ANCHOR PIN INSPECTION Description Location Observation

1. Rail clamp hydraulic unit - Check oil condition and level - Check piping, any leakage and hose condition - 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 All location Done( ) / Not Done( ) All location Good( ) / Not Good( ) All location Good( ) / Not Good( ) All motors Good( ) / Not Good( ) All units Good( ) / Not Good( )

330

- GANTRY ANTI-COLLISION CRANE TO SHIP INSPECTION Description Location Observation

1. Anti-collision limit switch - Check functionality - Check wire termination and micro switch condition 2. Wire rope - Check wire rope rusty and stringness Note : Fill up where applicable 3. Housekeeping All location Done( ) / Not Done( ) Right and left side of boom girder Good( ) / Not Good( ) Right and left side of boom girder Good( ) / Not Good( )


340

- GANTRY ALARM SYSTEM INSPECTION Description Location Observation

1. Siren - Check siren functionality and condition - Check wire termination condition 2. Warning light - Check bulb and motor condition - Check lamp cover and mounting condition - Check wire termination condition 3. Housekeeping All location Done( ) / Not Done( ) All warning lights Good( ) / Not Good( ) All sirens Good( ) / Not Good( )

350

- GANTRY WHEEL INSPECTION Description Location Observation

1. Wheel - Check wheel bearing condition and abnormal sound 2. Structure - Check wheel flange cracks or damages and condition - Check mounting condition 3. Housekeeping All location Done( ) / Not Done( ) All wheels Good( ) / Not Good( ) All wheels Good( ) / Not Good( )

General Remark :


360

- BOOM BRAKE INSPECTION - SERVICE BRAKE Description Location Brake #1 (Height : _________ mm) Good( Observation ) / Not Good( )

360.1

1. Reserve stroke height (10 mm) - Inspect stroke indicator setting and manual release 2. Braking torque - Inspect setting and mechanical componentNote : IMPSA-A : 1890Nm, NOELL/MITSUI/ZPMC-A: 14850 Nm, IMPSA-B : >7200Nm, ZPMC-B : >5940Nm, ZPMC-C: >6000Nm

Brake #1 (Torque : ________________ Nm)

Good(

) / Not Good(

)

3. Air gap - Check any rubbing 4. Brake pad and disc - Check and clean disc surface - Inspect pad and disc (Pad : 5 mm, Disc : 27 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 b. Brake release c. Brake pad wear Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) Service brake Good( ) / Not Good( ) Service brake Service brake Good( Good( ) / Not Good( ) / Not Good( ) ) Service brake Brake pad RHS : ________mm Brake pad LHS : ________mm Brake disc : ________mm Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) )

360.2

- EMERGENCY BRAKE Description Location Observation

1. Hydraulic power pack - Check oil condition and working pressure (150-180 bar) 2. Hydraulic cylinder and block - Check leakage 3. Proximity Sensor & Motor - Check setting and functionality - Check electrical and mechanical parts 4. Brake pad and disc - Inspect pad and disc (Pad : 8 mm, Disc : 28 mm) - Check and clean disc surface Note : Fill up where applicable Brake #1 RHS : ______mm , Disc : ______mm Brake #1 LHS : ______mm Brake #2 RHS : ______mm Brake #2 LHS : ______mm Brake #3 RHS : ______mm , Disc : ______mm Brake #3 LHS : ______mm Brake #4 RHS : ______mm Brake #4 LHS : ______mm 5. Housekeeping All location All location Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Done( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) ) ) ) ) ) ) ) ) Good( ) / Not Good( ) Hydraulic oil tank Good( ) / Not Good( )


370

- BOOM GEARBOX / REDUCER Description Location Observation

1. Gearbox oil - Inspect oil level and oil condition 2. Structure - Inspect mounting bolts tightness and crack 3. Bearing - Inspect abnormal sound 4. Temperature (40 ~ 60 degree) 5. Housekeeping Gearbox #1 Gearbox #1 : _________degree All location Good( Good( Done( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) Gearbox #1 Good( ) / Not Good( ) Gearbox #1 Good( ) / Not Good( )

380

- BOOM MOTOR Description Location Boom motor Good( Observation ) / Not Good( )

1. Sound inspection 2. Visual check - Check structure and wire termination 3. Emergency Motor - Check coupling condition - Check limit switch working condition 4. Housekeeping

Boom motor

Good(

) / Not Good(

)

Boom emergency motor

Good(

) / Not Good(

)

All location

Done(

) / Not Done(

)

390

- BOOM WIRE ROPE INSPECTION Description Location Observation

1. Visual check - Check broken strands, deformation and kinks - Broken strands (28.8mm, IMPSA-B : >34.2mm, 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 All plates All location Good( Done( ) / Not Good( ) / Not Done( ) ) Wire rope Good( ) / Not Good( ) Length #1 Length #2 Good( Good( ) / Not Good( ) / Not Good( ) ) Wire rope drum Boom tip A-Frame Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) )


400

- BOOM WIRE ROPE DRUM INSPECTION Description Location All drums All drums All drums All drums All location Good( Good( Good( Good( Done( Observation ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) ) )

1. Check wire rope anchor 2. Check bearing any abnormal noise 3. Check groove surface condition 4. Check structure and mounting 5. Housekeeping

410

- BOOM SHEAVE AND BEARING INSPECTION Description Location Boom tip A-Frame Good( Good( Good( Good( Good( Good( Good( Good( Done( Observation ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) ) ) ) ) ) )

1. Check groove condition any damaged or rope trace mark

2. Check locking / keeper plate condition

Boom tip A-Frame

3. Check bearing condition

Boom tip A-Frame

4. Structure and mounting - Check condition and bolt tightness 5. Housekeeping

Boom tip A-Frame All location

420

- BOOM MOTOR AND GEARBOX COUPLING INSPECTION Description Location All couplings Good( Observation ) / Not Good( )

1. Check abnormal sound 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

All couplings

Good(

) / Not Good(

)

All couplings

Good(

) / Not Good(

)

All couplings All location

Good( Done(

) / Not Good( ) / Not Done(

) )

General Remark :


430

- BOOM LIMIT SWITCH INSPECTION Description Location Observation

1. Cable / conduit - Check cable condition, insulation and cable lug 2. Limit switch - Check positioning, rusty, functionality and mounting 3. Striker - Check condition 4. Housekeeping A-Frame All location Good( Done( ) / Not Good( ) / Not Done( ) ) A-Frame Good( ) / Not Good( ) A-Frame Good( ) / Not Good( )

440

- BOOM CAM SWITCH INSPECTION Description Location Observation

1. Cable termination - Check cable damage and breakage at cable lugs 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 All location Done( ) / Not Done( ) Boom drum Good( ) / Not Good( ) Boom drum Good( ) / Not Good( ) All couplings Boom drum Good( Good( ) / Not Good( ) / Not Good( ) ) All switches Good( ) / Not Good( ) Boom drum Good( ) / Not Good( )

General Remark :


450

- BOOM LATCH INSPECTION Description Location Observation

1. Servolifter - Check oil condition and any leakage - Check linkage split-pin and conduit condition - 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 All location Done( ) / Not Done( ) A-Frame Good( ) / Not Good( ) A-Frame Good( ) / Not Good( ) Boom latch Good( ) / Not Good( ) All limit switches Good( ) / Not Good( ) A-Frame Good( ) / Not Good( )

General Remark :


460

- EMERGENCY STOP SYSTEM INSPECTION Description Location Electrical room (inside) PLC panel DC bus shift cub Machinery house Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Done( Observation ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) )

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

Trolley / hoist emergency station Trolley house inside Trolley house panel Boom emergency station Boom top outside Boom top inside Boom girder end

4. Cabin - Check functionality and condition Note : Fill up where applicable 5. Portal - Check functionality and condition Note : Fill up where applicable

Checker cabin panel Cabin operator console Boom opeartor cabin Portal landside left Portal landside right Portal seaside left Portal seaside right

6. Others - Check functionality and condition Note : Fill up where applicable 7. Housekeeping

Gantry operation station High voltage cable reel station TLS station All location

470

- FLOODLIGHT INSPECTION Description Location Boom tip Boom joint Boom center cross beam Boom center Good( Good( Good( Good( Good( Good( Observation ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) )

1. Boom floodlight - Check functionality and condition - Check wire termination

2. Trolley floodlight - Check functionality and condition - Check wire termination Note : Fill up where applicable 3. Machinery house - Check functionality and condition - Check wire termination Note : Fill up where applicable

Trolley platform Operator cabin

Seaside Right hand side Left hand side Landside RHS Landside LHS

Good( Good( Good( Good( Good(

) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good(

) ) ) ) )


Description 4. Backreach - Check functionality and condition - Check wire termination Note : Fill up where applicable 5. Portal beam - Check functionality and condition - Check wire termination Note : Fill up where applicable 6. Housekeeping

Location

Observation

Backreach Multi-functional platform

Good( Good(

) / Not Good( ) / Not Good(

) )

Right hand side Left hand side

Good( Good(


) )

All location

Done(

) / Not Done(

)

480

- OPERATOR CABIN INSPECTION Description Location Observation

1. Master controller / joystick - Check functionality and condition - Check wire termination 2. Electrical system - Check functionality and condition - Check wire termination - Check power supply functionality 3. Selector switch and push button - Check functionality and condition - Check wire termination 4. Indicator light - Check functionality and condition - Check wire termination 5. Consol - Check wire termination and condition 6. Foot siren - Check functionality and condition - Check wire termination 7. Structure - Check structure condition - Check wind screen/ glass condition Cabin door Access gate All bushings Handrail Access ladder Support beam Platform 8. Public access (PA) system - Check functionality and condition - Check wire termination 9. Operator seat - Check functionality and condition 10. Housekeeping Operator seat All location Good( Done( ) / Not Good( ) / Not Done( ) ) Amplifier and speaker Good( ) / Not Good( ) Good( Good( Good( Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) ) ) Siren Good( ) / Not Good( ) Right side consol Left side consol Good( Good( ) / Not Good( ) / Not Good( ) ) All location Good( ) / Not Good( ) Right side consol Left side consol Good( Good( ) / Not Good( ) / Not Good( ) ) Right side consol Left side consol Wall fan Cabin lamp Power socket Access gate limit switch Electrical panel Good( Good( Good( Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) ) )


490

- AIR-CONDITIONER INSPECTION Description Location Observation

1. Compressor - Check structure and condition - Check wire termination and functionality - Check gas quantity and any leakage Note : Fill up where applicable 2. Indoor unit - Check structure and condition - Check wire termination and functionality 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 All location Done( ) / Not Done( ) All location Good( ) / Not Good( ) All location Good( ) / Not Good( ) Control room Operator cabin Checker cabin Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) Control room Operator cabin Checker cabin Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) )

500

- SOFTWARE AND PROGRAM MONITORING Please see attachment (if any)

General Remark :


510

- MAIN HOIST SYSTEM GREASING Description Location Observation

1. Main hoist system - Pump-in new grease into greasing point Note : Fill up where applicable Headblock sheave Headblock twistlock Backreach-main hoist sheave Trolley platform-main hoist sheave Main hoist drum sheave 2. Housekeeping All location Done( Done( Done( Done( Done( Done( ) / Not Done( ) / Not Done( ) / Not Done( ) / Not Done( ) / Not Done( ) / Not Done( ) ) ) ) ) )

520

- TROLLEY SYSTEM GREASING Description Location Observation

1. Trolley system - Pump-in new grease into greasing point Note : Fill up where applicable Trolley sheave Trolley floating shaft Trolley plumber block Catenary wheel Catenary sheave Catenary McGill guide roller Backreach-catenary sheave Backreach rope tensioner bearing 2. Housekeeping All location Done( Done( Done( Done( Done( Done( Done( Done( Done( ) / Not Done( ) / Not Done( ) / Not Done( ) / Not Done( ) / Not Done( ) / Not Done( ) / Not Done( ) / Not Done( ) / Not Done( ) ) ) ) ) ) ) ) )

530

- BOOM SYSTEM GREASING Description Location Observation

1. Boom system - Pump-in new grease into greasing point Note : Fill up where applicable 2. Housekeeping All location Done( ) / Not Done( ) Boom drum Done( ) / Not Done( )

General Remark :


540

- PASSENGER LIFT INSPECTION Description Location Observation

1. Guide rail - 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 Inside carrier All location Good( Done( ) / Not Good( ) / Not Done( ) ) Carrier Good( ) / Not Good( ) Power cable Good( ) / Not Good( ) All push buttons Good( ) / Not Good( ) All floors Good( ) / Not Good( ) All brakes Good( ) / Not Good( ) Top of cabin Good( ) / Not Good( ) All location Good( ) / Not Good( ) All location Good( ) / Not Good( ) All location Good( ) / Not Good( )

550

- FIRE ALARM SYSTEM INSPECTION Description Location Observation

1. Electrical part - Check AC power LED light up - Determine standby battery condition ( 25.5 x 26.6 Vdc ) - Check any alarm LED light up from panel - 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 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( Good( ) / Not Good( ) / Not Good( ) ) Good( ) / Not Good( ) Machinery house - Zone 1 - Zone 2 - Zone 3 - Zone 4 - Main - Charger - Evacuate Good( Good( Good( Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) ) )


560

- MAINTENANCE HOIST CRANE INSPECTION Description Location Observation

1. Limit switch and functional test - Hoist up stop - Hoist up slow down - Hoist down stop - Trolley forward stop - Trolley forward slow down - Trolley backward stop - Trolley backward slow down - Gantry right stop - Gantry right slow down - Gantry left stop - Gantry left slow down 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 Electrical box All location Good( Done( ) / Not Good( ) / Not Done( ) ) Machinery house Good( ) / Not Good( ) Rubber buffer Hook block Good( Good( ) / Not Good( ) / Not Good( ) ) Machinery house Good( ) / Not Good( ) Machinery house Machinery house Machinery house Machinery house Machinery house Machinery house Machinery house Machinery house Machinery house Machinery house Machinery house Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) ) ) ) ) ) )

570

- AIR COMPRESSOR INSPECTION Description Location Observation

1. Compressor - Check oil level sufficient, air filter, V-belt, pressure gauge, 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 Machinery house All location Good( Done( ) / Not Good( ) / Not Done( ) ) Machinery house Good( ) / Not Good( ) Machinery house Good( ) / Not Good( )

General Remark :


580

- QC CHECKER CABIN INSPECTION Description Location Observation

1. Socket & power supply - Check mounting and condition 2. Check lighting condition and functionality 3. Intercomm - Check condition and functionality 4. Structure - Check mounting and condition - Check door and glass 5. Housekeeping All location Done( ) / Not Done( ) All location Good( ) / Not Good( ) Good( ) / Not Good( ) All location Cabin ceiling Good( Good( ) / Not Good( ) / Not Good( ) )

General Remark :


590

- BOOM FORESTAY INSPECTION Description Location Observation

1. Bushing - Check abnormal sound and vibration 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 A-Frame All location Good( Done( ) / Not Good( ) / Not Done( ) ) All supports Good( ) / Not Good( ) All location Good( ) / Not Good( ) All location Good( ) / Not Good( )

600

- BOOM SHEAVE INSPECTION Description Location All sheaves All sheaves Good( Good( Observation ) / Not Good( ) / Not Good( ) )

1. Check bearing condition 2. Check grove condition 3. Structure - Check mounting and condition 4. Housekeeping

All sheaves All sheaves

Good( Done(


) )

610

- BOOM CABIN INSPECTION Description Location Observation

1. Indicator bulb - Check condition and functionality 2. Check lighting condition and functionality 3. Structure - Check mounting and condition - Check door and glass 4. Intercomm - Check condition and functionality 5. Housekeeping All location Good( Done( ) / Not Good( ) / Not Done( ) ) All location Good( ) / Not Good( ) All indicators bulbs Cabin ceiling Good( Good( ) / Not Good( ) / Not Good( ) )

General Remark :


620

- GANTRY SYSTEM GREASING Description Location Observation

1. Gantry system - Pump-in new grease into greasing point 2. Housekeeping All boggies All location Done( Done( ) / Not Done( ) / Not Done( ) )

630


1. Boom system - Pump-in new grease into greasing point 2. Housekeeping All boom sheaves All location Done( Done( ) / Not Done( ) / Not Done( ) )

640

- MAIN HOIST WIRE ROPE LUBRICATION Description Location Observation

1. Main hoist wire rope - Check condition and lubricate wire rope 2. Housekeeping All main hoist wire ropes All location Done( Done( ) / Not Done( ) / Not Done( ) )

650

- TROLLEY WIRE ROPE LUBRICATION Description Location Observation

1. Trolley wire rope - Check condition and lubricate wire rope Note : Fill up where applicable 2. Housekeeping All location Done( ) / Not Done( ) All trolley wire ropes Done( ) / Not Done( )

660

- BOOM WIRE ROPE LUBRICATION Description Location Observation

1. Boom wire rope - Check condition and lubricate wire rope 2. Housekeeping All boom wire ropes All location Done( Done( ) / Not Done( ) / Not Done( ) )

670

- CATERNARY WIRE ROPE LUBRICATION Description Location Observation

1. Catenary wire rope - Check condition and lubricate wire rope Note : Fill up where applicable All caternary wire ropes Done( ) / Not Done( )

2. Housekeeping

All location

Done(

) / Not Done(

)


680

- MAIN CABLE REEL INSPECTION Description Location Observation

1. Motor - Check mounting and condition 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 - Check mounting and condition - Check any abnormal sound 6. Housekeeping All location Good( Good( Good( Done( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) ) Good( ) / Not Good( ) All mounting Good( ) / Not Good( ) Main power cable Good( ) / Not Good( ) Main cable reel motor Good( ) / Not Good( )

General Remark :


690

- BOOM BACKSTAY GREASING Description Location Observation

1. Boom backstay - Pump-in new grease into greasing point Note : Fill up where applicable 2. Housekeeping All location Done( ) / Not Done( ) All greasing points Done( ) / Not Done( )

700

- KBT COUPLING GREASING Description Location Observation

1. KBT coupling - Pump-in new grease into greasing point Note : Fill up where applicable Please see attachment (No. : 2. Housekeeping ) All location Done( ) / Not Done( ) Done( ) / Not Done( )

General Remark :


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 :

#REF! #REF! #REF! 4 of 38

HOIST : Page 3 of 8

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#REF! #REF! #REF! 14 of 38TROLLEY : Page 5 of 8

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GANTRY : Page 1 of 4

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AC/DC MEGGER : Page 1 of 1


QUAY CRANE PREVENTIVE MAINTENANCE CHECKLISTMONTH / 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 QUARTERLY PM

: Page 1 to page 30 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 : MAIN HOIST SYSTEM TROLLEY SYSTEM GANTRY SYSTEM BOOM SYSTEM AUXIALLARY SYSTEM GREASING

PREPARED BY :Date :

SIGNATURE :

Date : Date : Date : Date : Date :

VERIFIED BY :

SIGNATURE :

Date :


10

- MAIN HOIST BRAKE - SERVICE BRAKE Description Location Brake #1 (Height : _________ mm) Brake #2 (Height : _________ mm) Brake #3 (Height : _________ mm) Brake #4 (Height : _________ mm) Good( Good( Good( Good( Good( Good( Good( Good( Observation ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) ) ) )

10.1

1. Reserve stroke height (10 mm) - Inspect stroke indicator setting and manual release Note : Fill up where applicable

2. Braking torque - Inspect setting and mechanical component Note : IMPSA-A : 15.75kNm, NOELL/MITSUI : 14.85kNm, IMPSA-B : 27kNm, ZPMC-A : 12.6kNm ZPMC-A : 14.85kNm, ZPMC-C : 19kNm 3. Air gap - Check any rubbing 4. Brake pad and disc - Inspect pad and disc - Check and clean disc surfaceNote : Fill up where applicable All cranes (Pad : 5 mm, Disc : 27 mm) ZPMC-B (Pad : 3 mm, Disc :1.0mm wear) ZPMC-C (Pad : > 3 mm, Disc wear more than 20%)

Brake #1 (Torque : ________________ Nm) Brake #2 (Torque : ________________ Nm) Brake #3 (Torque : ________________ Nm) Brake #4 (Torque : ________________ Nm)

All brakes Brake #1 RHS : ______mm , Disc : ______mm Brake #1 LHS : ______mm Brake #2 RHS : ______mm , Disc : ______mm Brake #2 LHS : ______mm Brake #3 RHS : ______mm , Disc : ______mm Brake #3 LHS : ______mm Brake #4 RHS : ______mm , Disc : ______mm Brake #4 LHS : ______mm

Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good(

) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good(

) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) )

5. Check AWC condition - Check one way bearing and adjusting nut condition - Check gap AMC to catched plate - Check adjustment AWC pin drive 6. Check wedge and shackle kit Note : Fill up where applicable

Brake #1 Brake #2 Brake #3 Brake #4 Brake #1 Brake #2 Brake #3 Brake #4

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

All servolifters

Good( a. Brake manual release b. Brake release c. Brake pad wear All location Good( Good( Good( Done(

) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done(

) ) ) ) )

General Remark :


10.2

- EMERGENCY BRAKE ( MAIN & AUX) Description Location Mechinery House Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) Observation

1. Hydraulic Tank - Check oil condition - Check oil level - Check working pressure (150 -180 bar) - Check tank condition 2. Hydraulic cylinder and block - Check hoses leakage - Check solenoid coil & dim plugs - Check valve leakage & functions 3. Proximity sensor - Check setting and functionality Note : Fill up where applicable 4. Motor & Electrical Components - Check electrical termination - Measure Motor demands

Good( Good( Good(

) / Not Good( ) / Not Good( ) / Not Good(

) ) )

Good(

) / Not Good(

)

Good( Phase 1: _______(A) Phase 2: _______(A) Phase 3: _______(A) Good(


) )

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 Disc Plate#1 RHS : ______mm Disc Plate#1 LHS : ______mm Disc Drum#1 RHS : ______mm Disc Drum #1 LHS : ______mm Disc Plate#2 RHS : ______mm Disc Plate #2 LHS : ______mm Disc Drum#2 RHS : ______mm Disc Drum #2 LHS : ______mm Good( Good( Good( Good( Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) ) ) )

6. Housekeeping

All location

Done(

) / Not Done(

)

General Remark :


20

- MAIN HOIST GEARBOX / REDUCER Description Location Observation

1. Gearbox oil - 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 Gearbox #1 Gearbox #2 Gearbox #1 : _________degree Gearbox #2 : _________degree All location Good( Good( Good( Good( Done( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) ) ) Gearbox #1 Gearbox #2 Good( Good( ) / Not Good( ) / Not Good( ) ) Gearbox #1 Gearbox #2 Good( Good( ) / Not Good( ) / Not Good( ) )

30

- MAIN HOIST DRIVE & BLOWER MOTOR Description Location Motor #1 Motor #2 Motor #3 Motor #4 Good( Good( Good( Good( Good( Good( Observation ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) )


2. Check heater Note : For DC motor only 3. Visual check - Check coupling motor & gear box (Bush Coupling) - Check terminations - Check mounting bolts and frame Note : Fill up where applicable 4. Check blower motor cond. - Check rotation - Check running cond - Measure motor demands - Check coupling condition 5. Emergency Motor - Check coupling condition & chain link - Check limit switch working condition 6. Air Filter - Check clealiness

Motor #1 Motor #2

Motor #1 Motor #2 Motor #3 Motor #4 Motor #1 Motor #2 Motor #3 Motor #4

Good( Good( Good( Good( Good( Good( Good( Good(

) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good(

) ) ) ) ) ) ) )

Motor #1 Motor #2 Motor #1 Motor #2 Motor #3 Motor #4

Good( Good( Good( Good( Good( Good(

) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good(

) ) ) ) ) )

7. Housekeeping

All location

Done(

) / Not Done(

)


40

- MAIN HOIST WIRE ROPE INSPECTION Description Location Observation

1. Visual check - Check broken strands, deformation and kinks - Diameter (NOELL/ZPMC-A : 26.2mm~28.0mm) - Diameter (IMPSA : 26.7mm~28.5mm) - Diameter (MITSUI : 26.2mm~23.3mm) - Diameter (ZPMC-C : 32.00mm~29.76mm) - Broken strands (20% from 30mm, Pad >3mm - Check and clean disc surface Note : Fill up where applicable All brakes Brake #1 RHS : ______mm , Disc : ______mm Brake #1 LHS : ______mm Brake #2 RHS : ______mm , Disc : ______mm Brake #3 RHS : ______mm , Disc : ______mm Brake #3 LHS : ______mm Brake #4 RHS : ______mm , Disc : ______mm Brake #4 LHS : ______mm 5. Check AWC condition - Check one way bearing and adjusting nut condition Note : Fill up where applicable Brake #1 Brake #2 Brake #3 Brake #4 6. Check wedge and shackle kit Note : Fill up where applicable Brake #1 Brake #2 Brake #3 Brake #4 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 a. Brake manual release b. Brake release c. Brake pad wear All location Good( Good( Good( Good( Done( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) ) ) All servolifters Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) )

ZPMC(Pad : 3 mm, Disc : 1.0mm wear on each side) Brake #2 LHS : ______mm

General Remark :


160

- TROLLEY GEARBOX INSPECTION Description Location Gearbox #1 Gearbox #2 Gearbox #3 Gearbox #4 Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Done( Observation ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) )

1. Gearbox oil - 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

Gearbox #1 : _________degree Gearbox #2 : _________degree Gearbox #3 : _________degree Gearbox #4 : _________degree

5. Housekeeping

All location

170

- TROLLEY MOTOR INSPECTION Description Location Motor #1 Motor #2 Motor #3 Motor #4 Good( Good( Good( Good( Good( Good( Observation ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) )


2. Check heater condition Note : For DC motor only Note : Fill up where applicable 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 Motor #1 Motor #2 Good( Good( ) / Not Good( ) / Not Good( ) ) Motor #1 Motor #2 Motor #3 Motor #4 Motor #1 Motor #2 Good( Good( Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) ) Motor #1 Motor #2


Description 6. Carbon brush and holder - Check length and condition Note : For DC motor only

Location Motor #1 - Top (3 pcs) Motor #1 - Bottom (3 pcs) Motor #1 - Right (3 pcs) Motor #1 - Left (3 pcs) Motor #2 - Top (3 pcs) Motor #2 - Bottom (3 pcs) Motor #2 - Right (3 pcs) Motor #2 - Left (3 pcs) Good( Good( Good( Good( Good( Good( Good( Good( Done(

Observation ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) ) ) ) ) ) )

7. Housekeeping

All location

180

- TROLLEY WIRE ROPE INSPECTION Description Location Observation

1. Visual check - Check broken strands, deformation and kinks - Diameter (2 6.2mm~mm) - Broken strands ( 207Nm, ZPMC-B : >320Nm, ZPMC-C : 350Nm

All brakes

Good(

) / Not Good(

)

#5 : ______ mm) #6 : ______ mm) #7 : ______ mm) #8 : ______ mm)



) ) ) )

#5 : ______ mm) #6 : ______ mm) #7 : ______ mm) #8 : ______ mm)



) ) ) )

Lanside Torque : #1 : ______ Nm Torque : #2 : ______ Nm Torque : #3 : ______ Nm Torque : #4 : ______ Nm Seaside Torque : #1 : ______ Nm Torque : #2 : ______ Nm Torque : #3 : ______ Nm Torque : #4 : ______ Nm #5 : ______ Nm) #6 : ______ Nm) #7 : ______ Nm) #8 : ______ Nm) Good( Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) #5 : ______ Nm) #6 : ______ Nm) #7 : ______ Nm) #8 : ______ Nm) Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) )

4. Air gap - Check any rubbing 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 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 Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) ) ) ) ) ) ) ) ) ) Brake #1 RHS : _____mm, LHS _____mm Disc : _____mm Good( Good( ) / Not Good( ) / Not Good( ) ) All brakes


Description

Location

Observation

6. Brake pad and disc (Seaside) - Inspect pad and disc (Pad : 5 mm, Disc : 27 mm) - Check and clean disc surface Note : Fill up where applicable

Brake #1 RHS : _____mm, LHS _____mm Disc : _____mm 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

Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good(

) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good(

) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) )

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 - Check pivot pin, linkage, mounting and cover - Check limit switch setting and functionality 10. Housekeeping All brakes All brakes All location Good( Good( Done( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) All servolifters Good( ) / Not Good( ) All brakes

300

- GANTRY GEARBOX INSPECTION Description Location Observation

1. Gearbox oil - Inspect oil level and oil condition 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 Done( ) / Not Done( ) All couplings Good( ) / Not Good( ) All gearboxes Good( ) / Not Good( ) All gearboxes Good( ) / Not Good( ) All gearboxes Good( ) / Not Good( ) All gearboxes Good( ) / Not Good( )


310

- GANTRY MOTOR INSPECTION Description Location Observation

1. Sound inspection - Check any abnormal sound 2. Electrical - Check wire termination at motor termination box 3. Structure - Check cover, mounting and body codition 4. Housekeeping All motors All location Good( Done( ) / Not Good( ) / Not Done( ) ) All motors Good( ) / Not Good( ) All motors Good( ) / Not Good( )

320

- GANTRY RAIL CLAMP AND ANCHOR PIN INSPECTION Description Location Observation

1. Rail clamp hydraulic unit - Check oil condition and level - Check piping, any leakage and hose condition - 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 All location Done( ) / Not Done( ) All location Good( ) / Not Good( ) All location Good( ) / Not Good( ) All motors Good( ) / Not Good( ) All units Good( ) / Not Good( )

330

- GANTRY ANTI-COLLISION CRANE TO SHIP INSPECTION Description Location Observation

1. Anti-collision limit switch - Check functionality - Check wire termination and micro switch condition 2. Wire rope - Check wire rope rusty and stringness Note : Fill up where applicable 3. Housekeeping All location Done( ) / Not Done( ) Right and left side of boom girder Good( ) / Not Good( ) Right and left side of boom girder Good( ) / Not Good( )


340

- GANTRY ALARM SYSTEM INSPECTION Description Location Observation

1. Siren - Check siren functionality and condition - Check wire termination condition 2. Warning light - Check bulb and motor condition - Check lamp cover and mounting condition - Check wire termination condition 3. Housekeeping All location Done( ) / Not Done( ) All warning lights Good( ) / Not Good( ) All sirens Good( ) / Not Good( )

350

- GANTRY WHEEL INSPECTION Description Location Observation

1. Wheel - Check wheel bearing condition and abnormal sound 2. Structure - Check wheel flange cracks or damages and condition - Check mounting condition 3. Housekeeping All location Done( ) / Not Done( ) All wheels Good( ) / Not Good( ) All wheels Good( ) / Not Good( )

General Remark :


360

- BOOM BRAKE INSPECTION - SERVICE BRAKE Description Location Brake #1 (Height : _________ mm) Good( Observation ) / Not Good( )

360.1

1. Reserve stroke height (10 mm) - Inspect stroke indicator setting and manual release 2. Braking torque - Inspect setting and mechanical componentNote : IMPSA-A : 1890Nm, NOELL/MITSUI/ZPMC-A: 14850 Nm, IMPSA-B : >7200Nm, ZPMC-B : >5940Nm, ZPMC-C: >6000Nm

Brake #1 (Torque : ________________ Nm)

Good(

) / Not Good(

)

3. Air gap - Check any rubbing 4. Brake pad and disc - Check and clean disc surface - Inspect pad and disc (Pad : 5 mm, Disc : 27 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 b. Brake release c. Brake pad wear Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) Service brake Good( ) / Not Good( ) Service brake Service brake Good( Good( ) / Not Good( ) / Not Good( ) ) Service brake Brake pad RHS : ________mm Brake pad LHS : ________mm Brake disc : ________mm Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) )

360.2

- EMERGENCY BRAKE Description Location Observation

1. Hydraulic power pack - Check oil condition and working pressure (150-180 bar) 2. Hydraulic cylinder and block - Check leakage 3. Proximity Sensor & Motor - Check setting and functionality - Check electrical and mechanical parts 4. Brake pad and disc - Inspect pad and disc (Pad : 8 mm, Disc : 28 mm) - Check and clean disc surface Note : Fill up where applicable Brake #1 RHS : ______mm , Disc : ______mm Brake #1 LHS : ______mm Brake #2 RHS : ______mm Brake #2 LHS : ______mm Brake #3 RHS : ______mm , Disc : ______mm Brake #3 LHS : ______mm Brake #4 RHS : ______mm Brake #4 LHS : ______mm 5. Housekeeping All location All location Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Done( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) ) ) ) ) ) ) ) ) Good( ) / Not Good( ) Hydraulic oil tank Good( ) / Not Good( )


370

- BOOM GEARBOX / REDUCER Description Location Observation

1. Gearbox oil - Inspect oil level and oil condition 2. Structure - Inspect mounting bolts tightness and crack 3. Bearing - Inspect abnormal sound 4. Temperature (40 ~ 60 degree) 5. Housekeeping Gearbox #1 Gearbox #1 : _________degree All location Good( Good( Done( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) Gearbox #1 Good( ) / Not Good( ) Gearbox #1 Good( ) / Not Good( )

380

- BOOM MOTOR Description Location Boom motor Good( Observation ) / Not Good( )

1. Sound inspection 2. Visual check - Check structure and wire termination 3. Emergency Motor - Check coupling condition - Check limit switch working condition 4. Housekeeping

Boom motor

Good(

) / Not Good(

)

Boom emergency motor

Good(

) / Not Good(

)

All location

Done(

) / Not Done(

)

390

- BOOM WIRE ROPE INSPECTION Description Location Observation

1. Visual check - Check broken strands, deformation and kinks - Broken strands (28.8mm, IMPSA-B : >34.2mm, 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 All plates All location Good( Done( ) / Not Good( ) / Not Done( ) ) Wire rope Good( ) / Not Good( ) Length #1 Length #2 Good( Good( ) / Not Good( ) / Not Good( ) ) Wire rope drum Boom tip A-Frame Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) )


400

- BOOM WIRE ROPE DRUM INSPECTION Description Location All drums All drums All drums All drums All location Good( Good( Good( Good( Done( Observation ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) ) )

1. Check wire rope anchor 2. Check bearing any abnormal noise 3. Check groove surface condition 4. Check structure and mounting 5. Housekeeping

410

- BOOM SHEAVE AND BEARING INSPECTION Description Location Boom tip A-Frame Good( Good( Good( Good( Good( Good( Good( Good( Done( Observation ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) ) ) ) ) ) )

1. Check groove condition any damaged or rope trace mark

2. Check locking / keeper plate condition

Boom tip A-Frame

3. Check bearing condition

Boom tip A-Frame

4. Structure and mounting - Check condition and bolt tightness 5. Housekeeping

Boom tip A-Frame All location

420

- BOOM MOTOR AND GEARBOX COUPLING INSPECTION Description Location All couplings Good( Observation ) / Not Good( )

1. Check abnormal sound 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

All couplings

Good(

) / Not Good(

)

All couplings

Good(

) / Not Good(

)

All couplings All location

Good( Done(


) )

General Remark :


430

- BOOM LIMIT SWITCH INSPECTION Description Location Observation

1. Cable / conduit - Check cable condition, insulation and cable lug 2. Limit switch - Check positioning, rusty, functionality and mounting 3. Striker - Check condition 4. Housekeeping A-Frame All location Good( Done( ) / Not Good( ) / Not Done( ) ) A-Frame Good( ) / Not Good( ) A-Frame Good( ) / Not Good( )

440

- BOOM CAM SWITCH INSPECTION Description Location Observation

1. Cable termination - Check cable damage and breakage at cable lugs 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 All location Done( ) / Not Done( ) Boom drum Good( ) / Not Good( ) Boom drum Good( ) / Not Good( ) All couplings Boom drum Good( Good( ) / Not Good( ) / Not Good( ) ) All switches Good( ) / Not Good( ) Boom drum Good( ) / Not Good( )

General Remark :


450

- BOOM LATCH INSPECTION Description Location Observation

1. Servolifter - Check oil condition and any leakage - Check linkage split-pin and conduit condition - 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 All location Done( ) / Not Done( ) A-Frame Good( ) / Not Good( ) A-Frame Good( ) / Not Good( ) Boom latch Good( ) / Not Good( ) All limit switches Good( ) / Not Good( ) A-Frame Good( ) / Not Good( )

General Remark :


460

- EMERGENCY STOP SYSTEM INSPECTION Description Location Electrical room (inside) PLC panel DC bus shift cub Machinery house Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Done( Observation ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) )

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

Trolley / hoist emergency station Trolley house inside Trolley house panel Boom emergency station Boom top outside Boom top inside Boom girder end

4. Cabin - Check functionality and condition Note : Fill up where applicable 5. Portal - Check functionality and condition Note : Fill up where applicable

Checker cabin panel Cabin operator console Boom opeartor cabin Portal landside left Portal landside right Portal seaside left Portal seaside right

6. Others - Check functionality and condition Note : Fill up where applicable 7. Housekeeping

Gantry operation station High voltage cable reel station TLS station All location

470

- FLOODLIGHT INSPECTION Description Location Boom tip Boom joint Boom center cross beam Boom center Good( Good( Good( Good( Good( Good( Observation ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) )

1. Boom floodlight - Check functionality and condition - Check wire termination

2. Trolley floodlight - Check functionality and condition - Check wire termination Note : Fill up where applicable 3. Machinery house - Check functionality and condition - Check wire termination Note : Fill up where applicable

Trolley platform Operator cabin

Seaside Right hand side Left hand side Landside RHS Landside LHS

Good( Good( Good( Good( Good(

) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good(

) ) ) ) )


Description 4. Backreach - Check functionality and condition - Check wire termination Note : Fill up where applicable 5. Portal beam - Check functionality and condition - Check wire termination Note : Fill up where applicable 6. Housekeeping

Location

Observation

Backreach Multi-functional platform

Good( Good(


) )

Right hand side Left hand side

Good( Good(


) )

All location

Done(

) / Not Done(

)

480

- OPERATOR CABIN INSPECTION Description Location Observation

1. Master controller / joystick - Check functionality and condition - Check wire termination 2. Electrical system - Check functionality and condition - Check wire termination - Check power supply functionality 3. Selector switch and push button - Check functionality and condition - Check wire termination 4. Indicator light - Check functionality and condition - Check wire termination 5. Consol - Check wire termination and condition 6. Foot siren - Check functionality and condition - Check wire termination 7. Structure - Check structure condition - Check wind screen/ glass condition Cabin door Access gate All bushings Handrail Access ladder Support beam Platform 8. Public access (PA) system - Check functionality and condition - Check wire termination 9. Operator seat - Check functionality and condition 10. Housekeeping Operator seat All location Good( Done( ) / Not Good( ) / Not Done( ) ) Amplifier and speaker Good( ) / Not Good( ) Good( Good( Good( Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) ) ) Siren Good( ) / Not Good( ) Right side consol Left side consol Good( Good( ) / Not Good( ) / Not Good( ) ) All location Good( ) / Not Good( ) Right side consol Left side consol Good( Good( ) / Not Good( ) / Not Good( ) ) Right side consol Left side consol Wall fan Cabin lamp Power socket Access gate limit switch Electrical panel Good( Good( Good( Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) ) )


490

- AIR-CONDITIONER INSPECTION Description Location Observation

1. Compressor - Check structure and condition - Check wire termination and functionality - Check gas quantity and any leakage Note : Fill up where applicable 2. Indoor unit - Check structure and condition - Check wire termination and functionality 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 All location Done( ) / Not Done( ) All location Good( ) / Not Good( ) All location Good( ) / Not Good( ) Control room Operator cabin Checker cabin Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) Control room Operator cabin Checker cabin Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) )

500

- SOFTWARE AND PROGRAM MONITORING Please see attachment (if any)

General Remark :


510

- MAIN HOIST SYSTEM GREASING Description Location Observation

1. Main hoist system - Pump-in new grease into greasing point Note : Fill up where applicable Headblock sheave Headblock twistlock Backreach-main hoist sheave Trolley platform-main hoist sheave Main hoist drum sheave 2. Housekeeping All location Done( Done( Done( Done( Done( Done( ) / Not Done( ) / Not Done( ) / Not Done( ) / Not Done( ) / Not Done( ) / Not Done( ) ) ) ) ) )

520

- TROLLEY SYSTEM GREASING Description Location Observation

1. Trolley system - Pump-in new grease into greasing point Note : Fill up where applicable Trolley sheave Trolley floating shaft Trolley plumber block Catenary wheel Catenary sheave Catenary McGill guide roller Backreach-catenary sheave Backreach rope tensioner bearing 2. Housekeeping All location Done( Done( Done( Done( Done( Done( Done( Done( Done( ) / Not Done( ) / Not Done( ) / Not Done( ) / Not Done( ) / Not Done( ) / Not Done( ) / Not Done( ) / Not Done( ) / Not Done( ) ) ) ) ) ) ) ) )

530


1. Boom system - Pump-in new grease into greasing point Note : Fill up where applicable 2. Housekeeping All location Done( ) / Not Done( ) Boom drum Done( ) / Not Done( )

General Remark :


540

- PASSENGER LIFT INSPECTION Description Location Observation

1. Guide rail - 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 Inside carrier All location Good( Done( ) / Not Good( ) / Not Done( ) ) Carrier Good( ) / Not Good( ) Power cable Good( ) / Not Good( ) All push buttons Good( ) / Not Good( ) All floors Good( ) / Not Good( ) All brakes Good( ) / Not Good( ) Top of cabin Good( ) / Not Good( ) All location Good( ) / Not Good( ) All location Good( ) / Not Good( ) All location Good( ) / Not Good( )

550

- FIRE ALARM SYSTEM INSPECTION Description Location Observation

1. Electrical part - Check AC power LED light up - Determine standby battery condition ( 25.5 x 26.6 Vdc ) - Check any alarm LED light up from panel - 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 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( Good( ) / Not Good( ) / Not Good( ) ) Good( ) / Not Good( ) Machinery house - Zone 1 - Zone 2 - Zone 3 - Zone 4 - Main - Charger - Evacuate Good( Good( Good( Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) ) )


560

- MAINTENANCE HOIST CRANE INSPECTION Description Location Observation

1. Limit switch and functional test - Hoist up stop - Hoist up slow down - Hoist down stop - Trolley forward stop - Trolley forward slow down - Trolley backward stop - Trolley backward slow down - Gantry right stop - Gantry right slow down - Gantry left stop - Gantry left slow down 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 Electrical box All location Good( Done( ) / Not Good( ) / Not Done( ) ) Machinery house Good( ) / Not Good( ) Rubber buffer Hook block Good( Good( ) / Not Good( ) / Not Good( ) ) Machinery house Good( ) / Not Good( ) Machinery house Machinery house Machinery house Machinery house Machinery house Machinery house Machinery house Machinery house Machinery house Machinery house Machinery house Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Good( ) ) ) ) ) ) ) ) ) ) )

570

- AIR COMPRESSOR INSPECTION Description Location Observation

1. Compressor - Check oil level sufficient, air filter, V-belt, pressure gauge, 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 Machinery house All location Good( Done( ) / Not Good( ) / Not Done( ) ) Machinery house Good( ) / Not Good( ) Machinery house Good( ) / Not Good( )

General Remark :


580

- QC CHECKER CABIN INSPECTION Description Location Observation

1. Socket & power supply - Check mounting and condition 2. Check lighting condition and functionality 3. Intercomm - Check condition and functionality 4. Structure - Check mounting and condition - Check door and glass 5. Housekeeping All location Done( ) / Not Done( ) All location Good( ) / Not Good( ) Good( ) / Not Good( ) All location Cabin ceiling Good( Good( ) / Not Good( ) / Not Good( ) )

General Remark :


590

- BOOM FORESTAY INSPECTION Description Location Observation

1. Bushing - Check abnormal sound and vibration 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 A-Frame All location Good( Done( ) / Not Good( ) / Not Done( ) ) All supports Good( ) / Not Good( ) All location Good( ) / Not Good( ) All location Good( ) / Not Good( )

600

- BOOM SHEAVE INSPECTION Description Location All sheaves All sheaves Good( Good( Observation ) / Not Good( ) / Not Good( ) )

1. Check bearing condition 2. Check grove condition 3. Structure - Check mounting and condition 4. Housekeeping

All sheaves All sheaves

Good( Done(


) )

610

- BOOM CABIN INSPECTION Description Location Observation

1. Indicator bulb - Check condition and functionality 2. Check lighting condition and functionality 3. Structure - Check mounting and condition - Check door and glass 4. Intercomm - Check condition and functionality 5. Housekeeping All location Good( Done( ) / Not Good( ) / Not Done( ) ) All location Good( ) / Not Good( ) All indicators bulbs Cabin ceiling Good( Good( ) / Not Good( ) / Not Good( ) )

General Remark :


620

- GANTRY SYSTEM GREASING Description Location Observation

1. Gantry system - Pump-in new grease into greasing point 2. Housekeeping All boggies All location Done( Done( ) / Not Done( ) / Not Done( ) )

630


1. Boom system - Pump-in new grease into greasing point 2. Housekeeping All boom sheaves All location Done( Done( ) / Not Done( ) / Not Done( ) )

640

- MAIN HOIST WIRE ROPE LUBRICATION Description Location Observation

1. Main hoist wire rope - Check condition and lubricate wire rope 2. Housekeeping All main hoist wire ropes All location Done( Done( ) / Not Done( ) / Not Done( ) )

650

- TROLLEY WIRE ROPE LUBRICATION Description Location Observation

1. Trolley wire rope - Check condition and lubricate wire rope Note : Fill up where applicable 2. Housekeeping All location Done( ) / Not Done( ) All trolley wire ropes Done( ) / Not Done( )

660

- BOOM WIRE ROPE LUBRICATION Description Location Observation

1. Boom wire rope - Check condition and lubricate wire rope 2. Housekeeping All boom wire ropes All location Done( Done( ) / Not Done( ) / Not Done( ) )

670

- CATERNARY WIRE ROPE LUBRICATION Description Location Observation

1. Catenary wire rope - Check condition and lubricate wire rope Note : Fill up where applicable 2. Housekeeping All location Done( ) / Not Done( ) All caternary wire ropes Done( ) / Not Done( )


680

- MAIN CABLE REEL INSPECTION Description Location Observation

1. Motor - Check mounting and condition 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 - Check mounting and condition - Check any abnormal sound 6. Housekeeping All location Good( Good( Good( Done( ) / Not Good( ) / Not Good( ) / Not Good( ) / Not Done( ) ) ) ) Good( ) / Not Good( ) All mounting Good( ) / Not Good( ) Main power cable Good( ) / Not Good( ) Main cable reel motor Good( ) / Not Good( )

General Remark :


690

- BOOM BACKSTAY GREASING Description Location Observation

1. Boom backstay - Pump-in new grease into greasing point Note : Fill up where applicable 2. Housekeeping All location Done( ) / Not Done( ) All greasing points Done( ) / Not Done( )

700

- KBT COUPLING GREASING Description Location Observation

1. KBT coupling - Pump-in new grease into greasing point Note : Fill up where applicable Please see attachment (No. : 2. Housekeeping ) All location Done( ) / Not Done( ) Done( ) / Not Done( )

General Remark :


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 :

FM-M&R-QC002-000 000 15-Apr-10 1 of 38

QUAY CRANE MAINTENANCE CHECKLIST

UR METER READING :

LAND SIDE (FOR DUAL HOIST CRANE)

SEA SIDE (FOR DUAL HOIST CRANE)

M CHECKLIST TYPE :

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Documents

01+ +QC+Preventive+Maintenance+Checklist+(Drafted+Q34 Q44)(1)