lattice boom crawler crane - pickles

Accreditation no. 19898

Div of The Crane Industry Council of AustraliaABN 73 002 565 773

PO Box 136MOUNT WAVERLEY VIC 3149

P: +61 (03) 9501 0078E: [email protected]

LATTICE BOOM CRAWLER CRANEAnnual Report

Company ASC Pty Ltd ABN 45 051 762 639

Address 649 Mersey Road North OSBORNE Representative Mr Jeff Smith

State SA Phone 08 7423 4316

Postcode 5017 Email [email protected]

Make Manitowoc

Model 21000

Serial Number 2100 1014

Plant Number N/A

Year of Manufacture 2010

Design Registration Number NOT SIGHTED

Plant Registration NOT SIGHTED

Max Load 907000kg

Upper Hours 6838

Country where assessed Australia State SA

Operators Manual in English OK

Log Book OK

Maintenance Records OK

Crane Safety Manual No

Assessed By Phillip Young Company Titan Crane & Inspection Services Pty

LtdReg. No. SA1072 Address 12-14 Kenworth Road GEPPS CROSS

Phone 0429 993 308 State SA

Email [email protected] Postcode 5094

Initital Inspection Date 27/03/2019 Issued Date 15/04/2019

Re-Inspection Date 12/04/2019 Expiry Date 12/04/2020

Conforms to Checklist YesThis report is confirmation that the crane has undergone an annual inspection to the appropriate standard and is considered safefor continued operation at time of inspection.

Actions Required - NA

No. LBCC A 137269-8

Accredited for compliance with ISO/IEC 17020NATA is a signatory to the ILAC Mutual Recognition Arrangement for the mutual recognition of the equivalence of testing, medical testing, calibration and inspection reports

© The Crane Industry Council of Australia 2009All CraneSafe forms, checklists, surveys, audits and reports together with the embedded methodology contained within are the intellectual property of The

Crane Industry Council of Australia and may not be use without The Crane Industry Council of Australia's prior written consent.

of 23

BOOM AND ATTACHMENTS

Boom Base Section OKBoom Foot Pins and Bushings OKBoom Inserts OKBoom Point Section OKPoint Shaft and Sheaves OKBoom Point Guard OKIdler Sheaves OKBoom Hoist Limit OKSuspension Cables / Rods OKIntermediate Suspension N/ACable Rollers - Guards OKMast - Upper Spreader OKBackstops OKGantry OKLower Spreader OKBoom Angle Indicator OKBoom Base Sheave OKJib Base Section N/AJib Point Section N/AJib Inserts N/AJib Struts N/AJib Suspension Cables N/AFairlead N/ATag Line Winder N/ALuffing Jib(s) N/AHeavy Lift Attachments N/AAnemometer REMEDIED -

Boom Head OKRooster Sheave OKExtension / Fly N/A

HOOK BLOCKSDescription hook blockBranded WLL (kg) OK 544000kgManufacturers Identification OK - 01043957Safety Latches OKSheaves and Bearings OK - 15Swivel OKBranded with Tare Weight (kg) OK 16800kg

HOOK BLOCKS No. 2Description Aux HookBranded WLL (kg) OK 27000kgManufacturers Identification OK - 01044163Safety Latches OKSheaves and Bearings N/ASwivel OKBranded with Tare Weight (kg) OK 1200kg

No. LBCC A 137269-8



of 23

REVOLVING FRAME AND CABIN

Frame - Structural OKCounterweight - Security OK - to manufactures specificationCounterweight Hazard Striping N/A - spotters used when slewing and trackingCounterweight Lift Assembly N/AA Frame OKGear Case Cover(s) OKGaskets and Seals OKCab Glass and Mirrors OKSheet Metal and Paint OKSeat Assembly OKThrottle OKDead Man Controls OKFree Fall Lockout N/ADecals / Signs - In English OKLoad Charts in English as per AS1418 OKControl Levers - Clearly Marked OKControl Cables / Pilot Hoses OKHeater OKAir Conditioner REMEDIED - fan faulty repaired by ACMGauges OKAnti-Two block Alarms OKHorn OKAccess Steps OKDoors and Locks OKCab Mounts OKFront Wiper REMEDIED -Roof Wiper OKWindscreen Wiper / Washer OKSwitches and Relays OKInclinomoter OKFire Extinguisher OK

SLEW SYSTEM

Slew Transmission & Oil Level OK - oil level not checkedLeaks OKSwing Brake OKLock Valve(s) N/AHouse Lock N/ASlew Pinion OK - visualSlew Gear OK - visualSlewing Ring OK - visualBase Weld OK - visualSmooth Operation OKSlew Bolts OK - visualExcessive Bearing Play OK - visualExcessive Backlash OK - visualElectrical Swivel OKRoller Path N/ARoller Circle N/AHook Rollers N/ASlewing Rim N/A

No. LBCC A 137269-8



of 23

[[reportTextBelow]]

REAR DRUMSHAFT (HOIST) WINCH

Winch Condition & Oil Level OK - oil level not checkedClutch Assembly N/A - hydraulic driveClutch Band and Linings N/ACylinder and Swivel N/ABrake Band and Lining N/ABrake Control Linkage N/AOperating Cylinder(s) N/ADrum Locking Pawl Mechanism OKClutch Drum(s) N/ALagging N/AWire Rope OKCorrect Assembly and Connection of Jib HoistRope Socket

OK

Planetary Drum and Pinions N/APlanetary Band and Lining N/AOperating Cylinder(s) N/ABrake Control Linkage N/AGear Case Seal(s) OK

MAIN HOIST ASSEMBLY WINCH

Winch Condition & Oil Level OKClutch Assembly N/A - hydraulic driveClutch Band and Linings N/ACylinder and Swivel N/APlanetary Band and Lining N/ABrake Band and Lining N/APawls and Linkage OKOperating Cylinder(s) OKDrums and Wire rope OKCorrect Assembly and Connection of Hoist RopeSocket

OK

Boom Hoist Chaincase N/AShaft Assembly N/A

AUXILIARY HOIST ASSEMBLY WINCH

Winch Condition & Oil Level OKClutch Assembly N/A - hydraulic driveClutch Band and Linings N/ACylinder and Swivel N/APlanetary Band and Lining N/ABrake Band and Lining N/APawls and Linkage OKOperating Cylinder(s) N/ADrums and Wire rope OKCorrect Assembly and Connection of Hoist RopeSocket

OK

Boom Hoist Chaincase N/AShaft Assembly N/A

THIRD DRUM ASSEMBLY WINCH - NA

No. LBCC A 137269-8



of 23

[[reportTextBelow]]

HYDRAULIC SYSTEM

Hydraulic Reservoir & Oil Level OKReturn Filters and Housing OKSuction Lines and Hoses OKOil Cooler(s) OKMain Pump(s) OKSlew Pump OKPilot Pump N/ARelief Valves N/APressure Filter and Housing OKSlew Motor OKSlew Valve OKMain Winch Motor OKAuxiliary Winch Motor OKMain Winch Valve OKAuxiliary Winch Valve OKPressure Lines and Hoses OKAccumulator N/ACarbody Hydraulic System OKHydraulic Swivel OKHoses and Tubes OKPropel Transmission N/APropel Motors N/ARelief Valves N/APropel Brake N/AAxle Extension N/AControl Valve N/AHorizontal Cylinders N/AVertical Cylinders OK

AIR SYSTEMS - NA

ELECTRICAL SYSTEMS

Battery Box OKBattery Cables OKBattery Isolator OKStarter OKClearance Lights N/AFlood Lights N/ACircuit Breakers OKSwitches and Relays OKRotating Beacon(s) N/ASlew Alarm N/A - spotters usedTravel Alarm N/A - spotters used

No. LBCC A 137269-8



of 23

DRIVE SYSTEM

Radiator & Coolant Level OKRadiator Hoses OKFan OKFan Guard N/AOil Cooler(s) OKFuel Lines OKThrottle OKEngine Oil Pressure & Oil Level OKEngine Mounts OKPower Transmission Belts OKMuffler / Spark Arrestor OKAbnormal Engine Noises OKFuel Tank & Diesel Level OKEngine Warning System OKDrive Coupling N/APump Drives N/APump Disconnects (PTO) N/A

CRAWLER INSPECTION

Paint OKDecals / Signs - In English OKCarbody and Crawler Frames OKSide Frames and Axles OKConnecting Bolts OKDrive Sprockets OKIdler Sprockets OKCrawler Rollers OKPins and Bushings OKRoller Guards OKRail Assembly OKTrack Adjuster OKTension Spring Assembly N/ATrack Shoes OKPropel Chains N/APropel Clutch Shaft N/AClutch Drum(s) N/AClutch Assembly N/ABand and Lining N/ACylinders and Swivel N/ABevel Gears N/AVertical Propel Shaft N/AHorizontal Propel Shaft N/AOutboard Propel Shafts N/APropel Shaft Extension N/ASteering Assembly N/ABrake Drums N/ACrawler Brake Assembly N/ACarbody OKHydraulic Drive OKPlanetary Reductions OKDrive Motors OK

No. LBCC A 137269-8



of 23

Any third party testing is not included in the Crane Safe NATA accreditation.

FUNCTIONAL TESTS - MAIN WINCH

Load Chart Reference Number 8187 BM Maxer 110680kgPrinted Chart - No Load OK

Printed Chart Rated Capacity Indicator

Boom Angle, deg 51.30 51.20

Boom Length, m 85.30m 85.30m

Radius, m 56.00m 56.00m

Load, kg 84200kg 84400kg

o o

RCI Load Charts 75%

Load Chart Reference Number 8187 BM Maxer 110680kgRated Load in Stability OK - 40660kg 2 x counter weghts hook 16800 hook 1200kg 6400kg

winch rope

Rated Capacity Indicator Measured

Radius, m 66.00m 65.00m


Line Pull Test OK



Winch Brake Test OK



Overload Warning Lights and Alarms OKRated Capacity Limiter Fitted (Overload Limiter) OK

FUNCTIONAL TESTS - AUXILIARY WINCH

Load Chart Reference Number 8187 BMMaxer 110680kgRated Load in Stability N/ALine Pull Test OK



Winch Brake Test OK



Overload Warning Lights and Alarms OKRated Capacity Limiter Fitted (Overload Limiter) OK

CRACK INSPECTION

No Cracks Detected OK

ADDITIONAL ANNUAL INSPECTIONS STIPULATED BY THE MANUFACTURER - NA

No. LBCC A 137269-8



of 23

SITE REQUIREMENTS - NANo. LBCC A 137269-8



of 23

CRANE

ASSESSMENT

APPENDICES

Model

Serial Number

Upper Hours

No. LBCC A 137269-8



of 23

ASSESSMENT

BOOM AND ATTACHMENTS


Log Book

Anemometer

No. LBCC A 137269-8



of 23


REAR DRUMSHAFT (HOIST) WINCH

MAIN HOIST ASSEMBLY WINCH

Air Conditioner

Front Wiper

Correct Assembly and Connection of Jib Hoist Rope Socketboth ends of cable anchored at drum

No. LBCC A 137269-8



of 23

Correct Assembly and Connection of Hoist RopeSocket

No. LBCC A 137269-8



of 23

AUXILIARY HOIST ASSEMBLY WINCH


No. LBCC A 137269-8



of 23


No. LBCC A 137269-8



of 23

FUNCTIONAL TESTS - MAIN WINCH


Load Chart Reference Number

No. LBCC A 137269-8



of 23

Rated Load in Stability - Load RCI

No. LBCC A 137269-8



of 23

Rated Load in Stability - Radius Measured

No. LBCC A 137269-8



of 23

Rated Load in Stability - Radius RCI

No. LBCC A 137269-8



of 23

Rated Load in Stability - Load Measured

No. LBCC A 137269-8



of 23

Line Pull Test - Load RCI

No. LBCC A 137269-8



of 23

Customer: ASC Shipbuilding

Make: Manitowoc

Model: 21000

Serial No: 21001014 Job No: 305233

Service type/hrs: 1000hr MEX.No

SERVICE REQUIREMENTS 250 500 750 1000 Initials Note.no

Clean and check all windows for cracks P P P P J.K.

Clean all debris from crane P P P P J.K.Check for leaks (fuel, coolant, gear oil, engine oil, hydraulic

oil) Correct cause & fill faulty unit to proper level P P P P H.P.

Apply open gear oil to ring gear P P P P J.K.

Check fuel tank level & drain water from bottom of tank P P P P J.K.Check radiator coolant level when cold. Check Auto lube

system P P P P J.K.

Service engine P P P P H.P.

Check that fire extinguisher is on crane & fully charged P P P P H.P.Check that operators manual & capacity charts are in

operator's cab P P P P J.K.Check operating limit & system fault alerts for proper

operation - red & yellow lights, buzzer & beeper should

come on for approx. 3 seconds when cab power switch is on

& ignition switch is move to RUN position P P P P J.K.Check seat switch for proper operation - all control handles

& corresponding function should be inoperable when

operator is out of seat P P P P J.K.

107410

Workshop departure

Site arrival

Site departure

Workshop arrival

Technician Name: Johnathon/Harry

Possible rear main quick

couplings leaking

Date: 10.07.2018

Hour Meter: 6802

Key Points

MANITOWOC 21000 SERVICE REPORT

Page 1


Check digital display on control console for proper readings P P P P J.K.Replace hydraulic filters if digital display indicates need &

system fault alert is on (oil at operating temperature) P P P P

Check swing lock for proper operation, must hold crane in

position when engage & allow crane to swing when

disengaged P P P P J.K.Check each drum pawl for proper operation, must fully

engage & disengage ratchet P P P P J.K.Check park modes for proper operation - handles &

corresponding functions (drum or travel) must be

inoperable when park switches are on P P P P J.K.

Test each drum brake for proper operation with load lifted a

few feet off ground. While slowly hoisting or lowering,

move drum handle to off. Load must come to complete stop P P P P J.K.Check that boom hoist brake holds boom in position when

boom hoist handle is off P P P P J.K.Test travel brakes while slowly traveling in either direction.

Move crawler to off. Crane must come to complete stop &

brakes must hold crane in position. P P P P

Check that swing holding brake holds upper works in

position when swing handle is off. Handle should be

inoperable. P P P P J.K.Test rotation indicators for proper operation. P P P P J.K.Check load moment indicator for proper operation. P P P P J.K.

Check that wire rope is spooled properly on drums &

through sheaves before raising boom & loads from ground. P P P P J.K.Grease crane and MAXER P P P P H.P.

SERVICE REQUIREMENTS 250 500 750 1000 Initials Note.noKey Points

Unable to test drive due to

area restrictions

Key Points

Page 2

Oil all pins not equipped with grease fittings P P P P H.P.Check battery electrolyte level P P P P J.K.Inspect rotating bed, car body, crawler, & all beams for

cracks or other damage P P P P J.K.Check that all pins are in place & properly retained in

rotating bed, car body, crawlers & all beams P P P P J.K.Check that all bolts & screws are in place & tight in rotating

bed, carry body, crawlers & all beams. P P P P J.K.Check crawlers for proper adjustment P P P P J.K.Inspect that all boom & gantry pins & bolts are in place &

tight P P P P

Inspect all sheaves for wear and damage P P P P J.K.Inspect all wire rope for broken wires or excessive wear and

for proper spooling on drums & reeving through sheaves;

lubricate wire rope if needed. P P P P J.K.

Inspect each hook for cracks or deformation P P P P

Clean breather on hydraulic tank, on each planetary gear

box, on pump drive & on hydro-coupler pumps P P P P J.K.Test all disc brakes (Drum, swing, travel) for proper

operation P P P P N/ATest each limit device for proper operation P P P P

- Boom up limit P P P P

- Boom down limit P P P P

- Minimum bail limit P P P P

- Maximum bail limit P P P P

- Block up limit P P P P

- Any other limit crane is equipped with P P P P

Main winch 1st boom sheave seized

Unable to do due to area restrictions








Page 3


Check maxxer tire pressure (if equipped) & reinflate as

required P P P P J.K.Check level of pump drive and each planetary gear box P P P P J.K.

Check adjustment of boom angle indicator potentiometer P P P P J.K.Engage & disengage engine clutch several times with engine

running to clean discs P P P P J.K.Check tension of V-belts (See engine manual) P P P P H.P.Service battery (Clean and inspect) P P P P J.K.Check load moment indicator for proper calibration P P P P J.K.Replace Engine oil P P P P H.P.Replace engine oil filter P P P P H.P.Replace fuel filters x 2 P P H.P.replace fuel water seperation filter P P H.P.

Replace air filter x 2 P P H.P.

Replace coolant filter P P H.P.

Replace hydraulic tank filters x 2 P H.P.

Replace pump filters x 13 P H.P.

Hydraulic tank breather filter x 1 P J.K.

Airconditioning filter cab P H.P.

Kideny filters x 2 P H.P.

Oil sample right front outer hub P J.K.

Oil sample right front inner hub P J.K.

Oil sample left front outer hub P J.K.

Oil sample left front inner hub P J.K.

Inspected - All good

Key PointsVisual inspection

2 degrees out

Page 4

Oil sample right rear outer hub P


Oil sample right rear inner hub P J.K.

Oil sample left rear outer hub P J.K.

Oil sample left rear inner hub P J.K.

Oil sample hydraulic oil P J.K.

Oil sample main winch P J.K.

Oil sample aux winch P J.K.

Oil sample luffing winch P

Oil sample engine oil P

Sample coolant P J.K.

Oil sample pump drive gearbox P J.K.

Oil sample hydro coupler pumps P J.K.Check maxer tyre wheel nut torque P J.K.

Check slew ring bolt tensions P J.K.

Oil sample slew box x 4 J.K.

Clean computer filter J.K.

Visual inspection

Key Points

Visual inspection

Page 5

Filters for 250/750 hour service Replaced

LF9080 x 2 Lube Filter

FS19763 X 1 Fuel Water Separator

AF458 x 2 Air Filter

Filters for 500 hour service Replaced

LF9080 x 2 Lube Filter

FS19763 X 1 Fuel Water Separator

AF458 x 2 Air Filter

FF5644 x 2 Fuel Filter

WF2076 x 1 Coolant Filter

Filters for 1000 hour service Replaced

LF9080 x 2 Lube Filter Yes

FS19763 X 1 Fuel Water Separator Yes

AF458 x 2 Air Filter Yes

FF5644 x 2 Fuel Filter Yes

WF2076 x 1 Coolant Filter

HF6553 x 12 Hydraulic Filters Yes

HF6587 x 2 Hydraulic Filters Yes

Kleen Oil Filters KF50 x 2 Yes

Oil sample kits x 18 Yes

Page 6

No

te. N

o

Ph

oto

R/

Tim

e

Sta

tus

1 hr Repaired

4 hr Repaired

2 hr RR

M

3 hr M

4 hr M

M

4 hr RR

M

5 hr RR

3 hr Repaired

RR

4 hr Repaired

RR

M

M

RR

RR

RR

Main winch 1st sheave seized

Minor oil leak from control valve fittings behind engine

Fill up auto greasers at 50%

Inspect/grease hooks

Top up hydraulic level

Check boom

Check sheaves

Maxxer LHS pendant ram wiper seal keeps coming out/loose

All walkway grip tape perished

All tracks require removal of excess grease - Falling on ground

Front walkway support rails very rusty

LHF track 1 main support pin (lower front) stopper welds cracked

Cab roof & around front window very rusty

Hydraulic quick coupling on top of engine bay leaking

Boom hose quick coupling front of crane leaking

Possibe rear main seal leaking - requires cleaning and investigation

Notes & Comments

Cab roof insulation falling down

Cab door slides bent - door very hard to open and shut

Cal seat back rest loose/bent

Maxxer RH outrigger gland seals minor leaks - (2 x ram reseal)

RHF maxxer outrigger valve block minor leak

Maxxer main control valve 3rd & 5th spool leaking - Requires all spools cartridges to be removed

Maxxer LH outrigger gland seals leaking

Maxxer RH wheel rotational motor leaking

Page 7

lattice boom crawler crane - pickles

Documents