maintenance manual
Telescopic BOOM CRANE
LHC 11.0/20.0-14
PROJECT:
MODEL:
CLIENT:
DATE:
VERSION:
Choorhoekseweg 3
1280
LHC 11.0/20.0-14
Damen Shipyards Gorinchem
02-03-2015
1
4424NW
Wemeldinge
the Netherlands
Maintenance manual LHC 11.0/20.0-14
Tel. +31 (0) 113 – 621 385
Fax. +31 (0) 113 – 622 591
Table of contents :
1.
Introduction
1.1 Foreword ....………….……………………………………………………. 4
1.2 Document status ……………….………………………………………… 4
1.3 Important notice ……………………….…………………………………… 5
2.
Maintenance
2.1 General……………………………………………………………………... 6
2.2 Qualified persons………………………………………………………….. 6
2.3 Maintenance intervals…………………………………………………….. 7
3.
Lubrication schedule………………………………………………………… 11
4.
Oil filling schedule …………………………………………………………… 11
5.
Lubrication Pivot points………………………………………………………12
6.
Slewing gearboxes
6.1 General inspection…………………………………………………………
6.2 Tightening torques…………………………………………………………
6.3 ATEX provisions…………………………………………………………...
6.4 Lubricant inspection ………………………………………………………
6.5 Lubrication / oil type…………………………………………………….....
6.6 After the first 500 - 1000 working hours…………………………………
6.7 Every 100 hours op operation……………………………………………
6.8 Every 500 hours of operation. ……………………………………………
6.9 Every 2500 hours of operation……………………………………………
13
13
13
14
15
16
16
16
16
7.
Slewing bearing – Tilt Measurement
7.1 operations…………………………………………………………………... 18
7.2 Lubrication / oil type……………………………………………………..... 19
8.
Main hoisting winch gearbox
8.1 Cleaning……………………………………………………………………. 20
8.2 Routine maintenance……………………………………………………... 20
8.3 Extraordinary maintenance………………………………………………. 20
8.4 After the first 100 hours of operation. …………………………………... 20
8.5 Every 500 hours of operation…………………………………………….. 21
8.6 Every 1,000 hours of operation………………………………………...… 21
8.7 Every 2,000 hours of operation or at least once every 12 months…… 21
8.8 Every 5,000 hours of operation………………………………………….. 21
8.9 Main winch data…………………………………………………………… 21
9.10 Lubrication / oil type……………………………………………………... 22
8.11 Troubleshooting………………………………………………………….. 23
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9.
Cable
9.1 Cable inspection……………………………………………………………
9.2 Cable lubrication…………………………………………………………...
9.3 Installing the winch cable with a thimble………………………………...
9.4 Installing the winch cable with clamps…………………………………..
9.5 Start-up information after installing new cable………………………....
24
26
28
28
29
10.
Pulleys and drums
10.1 Inspection of pulleys and drums………………………………………… 30
10.2 Measuring the groove radius……………………………………………. 30
10.3 Pulleys Data………………………………………………………………. 31
11.
Correct spooling procedure on a drum…………………………………… 32
12.
Hydraulic
12.1 lines and hoses…………………………………………………………… 33
12.2 Replacement and inspection …………………………………………… 33
12.3 Oil………………………………………………………………………….. 34
12.4 Maintenance……………………………………………………………… 34
12.5 Regular maintenance……………………………………………………. 34
12.6 Filters……………………………………………………………………… 34
12.7 Viscosity…………………………………………………………………... 35
12.8 Oil condition index (OCI) ……………………………………………….. 35
13.
Service………………………………………………………………………….. 38
14.
Disposal installation…………………………………………………………. 38
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1. Introduction
1.1 Foreword
Lagendijk Equipment is a family company that has specialized in building service
cranes, cargo cranes and special crane projects at the top end of the market.
Products are specially designed for customers in the international offshore,
dredging and shipping industry.
Founded over 110 Years ago and drawing on its years of experience, the
company has concentrated on manufacturing customized machinery and
equipment. Complex structures and (hydraulic) installations can be developed
and built in house, in our independent engineering department and machinery
factory.
Lagendijk Equipment has its own 24 hour service department and is pleased to
provide customized solutions.
Contact:
Lagendijk Equipment
4424NW Wemeldinge
The Netherlands
T +31 (0)113-621385
F +31 (0)113-622591
The documentation for this machine is maintained on a customer basis. Please
therefore inform us, if you:



Sell the machine on
Purchase the machine from a previous owner
Take the machine out of service
1.2 Document status:
This documentation has been specifically created for the machine supplied with this
serial number and is not transferrable to other machines from the same range.
In order to ensure that the documentation is constantly up to date:
o Do not remover any documents (request these from the manufacture)
o Exchange outdated versions as soon as possible and destroy old versions
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1.3 Important notice
It should be stressed that the fitting of spare parts, other than those supplied by
Lagendijk Equipment, or the alteration of existing equipment without the
manufacturer`s permission, could render invalid the Lagendijk Equipment guarantee.
Only qualified personnel should work on this equipment.
Lagendijk Equipment reserves the right to modify data within this handbook at any
time, without any obligation to inform.
Before using the crane, it is necessary that you have a perfect knowledge of its
operations as well as of its safety rules. Therefore read carefully all the instructions
included in this handbook, this will prevent you from possible accidents.
All information in this manual is supplied solely as a guide to assist those responsible
for the operation and maintenance of the designated equipment.
This document is confidential. The copyright is vested in Lagendijk Equipment BV.
All rights reserved. Neither the whole nor any part of this document may be disclosed
to any third party or reproduced, stored in any from or by means (mechanical,
electronic reprographic, recording or otherwise) without the prior written consent of
the copyright owner.
© Lagendijk Equipment 2013
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2. Maintenance
2.1 General
This chapter lists all maintenance works that have to be carried out on the crane.
However, only the works the crane operator may perform by himself.
Maintenance work after 500 operating hours may only be carried out by qualified
personnel respectively authorized by Lagendijk Equipement to do so or by
Lagendijk-customer Service represtentative.
2.2 Qualified persons
Persons responsible for the safety of the crane must ensure that :
- qualified persons are only delegated to work on the machinery or apparatus,
- these persons must keep the operating manual provided, and other document
available when carrying out the operations to which they refer and follow that
documentation without fail.
- un authorized persons are prohibited from working on, or approaching the
machinery or apparatus.
Qualified persons are persons who, as result of their training, experience and the
instruction they have received , and of their knowledge of the relevant standards,
directives, accident prevention regulations and operating conditions, have been
authorized by those responsible for the safety of machine to carry out the particular
task required and who are able to recognize and avoid the potential hazards. A
knowledge of first-aid and local rescue equipment is essential. According
regulations, unqualified personnel are forbidden to work for example on power
installations on apparatus.
Note!
The specified maintenace and inspection intervals must not be exceeded.
When required, shorten the given intervals
Whenever the crane will not be in use for at least 3 months, all exposed parts must
covered and protected against the environment. The protective covers have to be
removed befor restarting the crane.
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2.3 Maintenance intervals
The maintanance intervals mentioned in this section are guiding times and should be
observed. If due to extreme enviromental conditions (i.e. dust tropical conditions) or
extreme operational conditions (i.e. multiple shift operation) a deviation to the given
maintenance interval(s) should becom necessary, ask Lagendijk Equipment for
advice and confirmation to do so.
It should be noted that in particular the maintenance time intervals indicated are
approximate. In reality these intervals should depend on crane usage and therefore
– may need to be updated accordingly.
The maintenance intervals indicate in the maintenance list are based on the actual
operating hours of the crane. Should the crane be standing for a period of more then
four (4) weeks- the crane has to be operated once a month for at least two (2) hours.
In addition to that all the greasing, oil inspections and oil level checks have to be
done as well.
10 h / daily
50 h / weekly
100 h / 2 weeks
250 h
500 h / 3 months
1000 h / 6 months
2000 h / every year
General maintenance
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X = Repeated maintenance
LE= Lagendijk Service personnel
Check function and corect indication of all
control devices
Check correct function of emergency stops
Check cables and plug connection of main
sensors
Check screw connections, cable sleeve
Check-up of steel structure, welds,
brackets, ladders, platforms.
Drive all functions, check safety devices
and limit switches
Check all terminals and ventilation of
switch cabinet
Check junction boxes
Check correct fit of cables and sensors
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10 h / daily
50 h / weekly
100 h / 2 weeks
250 h
500 h / 3 months
1000 h / 6 months
2000 h / every year
Greasing system
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X = Repeated maintenance
LE= Lagendijk Service personnel
Check all greasing lines
Check greasing points
Regrease all greasing points
Visual check of all greasing points, check
tightness of graesing lines.
Regrease all greasing points
Regrease all greasing points, greasing
lines and blocks.
10 h / daily
50 h / weekly
100 h / 2 weeks
250 h
500 h / 3 months
1000 h / 6 months
2500 h / every year
Slewing gearboxes and slewing bearing
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X = Repeated maintenance
LE= Lagendijk Service personnel
Check condition of gear rim, regrease
Check condition of slewing bearing,
regrease
Check gear oil level of slewing gearboxes
Grease slewing gear rim
Check correct oil level of slewing gear
boxes
Check air breather of slewing gear boxes
Take oil sample on slewing gearboxes,
check oil level
Take grease sample on slewing ring
Drive to temperature, take oil sample, if
required renew oil to correct level
Check correct torque of bolts of slewing ring
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10 h / daily
50 h / weekly
100 h / 2 weeks
250 h
500 h / 3 months
1000 h / 6 months
2000 h / every year
Hydraulic system
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X = Repeated maintenance
LE= Lagendijk Service personnel
W= Check weekly
Checking tighness and condition (hoses,
pipes,fittings)
Replace filter element of feed pressure
filter.
Drive system to working temperature
check leak tightness
Check wear of tooth profile of hydraulic
motors
Check pressure adjustments if required
LE
LE
10 h / daily
50 h / weekly
100 h / 2 weeks
250 h
500 h / 3 months
1000 h / 6 months
2000 h / every year
Ropes, rope pulleys and crane block
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X = Repeated maintenance
LE= Lagendijk Service personnel
Check condition, lubricants, function of
ropes
Check condition an rope fix points
Check for damages / wear of rope pulleys
Check for dammages / wear crane block
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10 h / daily
50 h / weekly
100 h / 2 weeks
250 h
500 h / 3 months
1000 h / 6 months
2000 h / every year
Hoisting winches
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X = Repeated maintenance
LE= Lagendijk Service personnel
Check correct function of limit switches
Check gear oil, grease counter bearing
Take oil samples, if required renew oil to
correct level. Befor fitting new oil flush the
gear boxes with little preheated oil in order
to wash off any contamination.
Check for corect oil level, check air
breathers
Execute disc brake test procedure
Drive to temperature, take oil samples, if
required renew oil to correct level. Before
fitting new oil flush the gear boxes with
little preheated oil in order to wash off any
contamination. Check level after a short
while again.
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3. Lubrication schedule
Lubricants and service fluids should be selected from the specifications.
Nr.
1.
2.
3.
4.
5.
3,4,5
6.
7.
8.
11
System
Slewing ring
Luffting cylinder pin (tube side)
Mainpin (left)
Mainpin (right)
Luffting cylinder pin (rod side)
Central grease point
Crane block
Slide pads boom
Bearing slewing gears
Wire rope
4. Oil filling schedule
Nr. System
9. Slewing gear box
10. Main hoisting winch
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5. Lubrication all pivot points
Equipment
Pivot points (2, 3, 4, 5)
Lubrication type
(suitable for temp -20 °C and +120 °C)
KROON OIL
Multipurpose grease 2
AGIP
GRMU EP2
BR
LS-EP2
ESSO
Become EP2
SHELL
Gadus S2 A320 2
MOBIL
Mobilux EP2
4
After the first 50 hours of use and then after
every 100 hours of use
The operating of pumping grease should be
carried out while the crane is stopped and should
be considered complete when the grease leaks
from the seal and forms a light film.
Before and after long periods of disuse of the
machine, a new bearing lubrication should be
carried out.
Number of grease nipples
Interval of lubrication
How to
Additional information
Central grease point.
Located in the column is a central grease point. It contains 3 grease nipples.
Reading from nipples left to right: 1=Main pin left
2=Main pin Right
3=Cylinder rod
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6. Slewing gearboxes
6.1 GENERAL INSPECTIONS
All works should be carried out by adequately prepared operators and in observance
of the safety rules in force.
Our assistance service is at your disposal for any need. Check often for strange
variations of temperature and/or noise.
Life of seals depends on various factors such as speed, temperature and
environment, and could vary between 4000 and 20000 hours.
Inspect the gear unit every two years. Check the screws tightening at the end of the
Running-in period and then every 2000h. In case the gearbox is fitted with a
coupling, we suggest to periodically check the wearing condition of the elastic
components, verifying that installation conditions have not been modified as well.
Ensure (once a month) that filler and lubricant drain plugs are correctly closed.
Periodically clean the outer surfaces of the gearbox, remove the dirt that could have
settled in time and that could limit heat dispersion.
6.2 Tightening torques
Recommended screws tightening torques (Nm) according UNI 5739 mat.8.8.
6.3 ATEX PROVISIONS
In dusty operation environments make sure to put in place an appropriate regular
cleaning plan for the outer surface of the gearbox so that the layer thickness does
not exceed 5mm
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6.4 LUBRICANT INSPECTION
Check monthly the oil level. Change the oil when gear unit is still in temperature.
Before replacing lubricant, always make sure that the product has not been operated
for at least 30 minutes, so that the temperature has dropped to a level not dangerous
for the operator.
Before filling the gear unit with new oil, first pour some oil of the same type to
remove particles remained inside the casing.
Make sure the new oil is introduced when no impurities are present.
Check for lubricant leakages.
If the product remains unused for a long time in a moist environment (e.g. RH above
50%), completely fill it up with oil. Before starting it, you will obviously need to restore
lubricant level first.
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6.5 Lubricant / oil type
Equipment
Bearing Slewing Gear (8)
Grease type
(suitable for temp -20 °C and +120 °C)
KROON OIL
Multipurpose grease 2
SHELL
Gadus S2 A320 2
MOBIL
Mobilux EP2
1 (per gearbox)
After the first 50 hours of use and then after
every 100 hours of use
The operating of pumping grease should be
carried out while the slewing drive is rotating and
should be considered complete when the grease
leaks from the seal and forms a light film.
Number of grease nipples
Interval of grease lubrication
How to
Equipment
Slewing Gearbox (9)
Oil type
BP
Energol GRXP-150
Shell
Tivella S 320
Mobil
Mobilgear 629
Check monthly the oil level
After 2500 hours of use the oil should be
changed
Before and after long periods of disuse of the
machine, new grease lubrication should be
carried out.
Interval
Additional information
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Equipment
Teeth Pinion (10)
Grease type
(suitable for temp -20 °C and +120 °C)
KROON OIL
Multipurpose grease 2
SHELL
Gadus S2 A320 2
MOBIL
Mobilux EP2
After the first 50 hours of use and then after
every 100 hours of use
Use a brush for greasing the teeth of the slewing
ring and pinion. To reach all teeth rotate the
slewing ring some degrees. The lubricant must
completely cover the sides of the teeth.
Before and after long periods of disuse of the
machine, new teeth lubrication should be carried
out.
Number of grease nipples
Interval of grease lubrication
How to
Additional information
6.6 After the first 500 - 1000 working hours.
- change the oil;
- clean the plugs;
- remove all metal residuals from the magnetic plug, making sure there are no big
fragments; if there are, contact Lagendijk Equipment service;
- check tightness of all the screws.
6.7 Every 100 hours of operation:
- Grease lubrication point
- Grease teeth pinion
6.7 Every 500 hours of operation:
- Visually check the oil level by way of the plugs;
- Check for lubricant leakages.
Every 2500 hours of operation:
- Change oil
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7. Slewing bearing – Tilt Measurement
Roller bearings have when deliverd, a certain amount of clearance. This guarantees
efficient rotation and safe functioning. Therefore it is necessary to check the bearing
clearance from time to time to ensure a safe functioning of the bearing unite.
First measurement
Wear of the bearing raceways results in a setting of the bearing ring, which is fixed at
the upper structure. The first measurement has to be carried out in new condition.
The same measurement with the same pre-conditions ( hook size, boom radius,
measuring gauge, no load, etc) have to be performed at least once a year and the
resulting values should be added to the following mentioned table :
Customer
Year of manufacture
Order no.
2015
1280
Repeated measurements (every 12 months )
Measuring point
Basic
measurement
1
2
3
4
5
6
7
8
9
10
pos.1
pos.2
pos.3
pos.4
Date
Grease-sample no.
Fe-magn,particle %
Service hours
1
2
3
4
5
* If a significant increase in wear is found, the measurement must be carried out at shoter intervals
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The measurement is made as shown in the sketches, between the lower structure
and the bearing ring, which is screwed to the upper structure. The measurement
itself is carried out with a suitable instrument having an accuracy of 1/10mm (caliper,
depth gauge).
7.1 Operations
1.
2.
3.
4.
5.
Use a 0.01 mm precision comparator, positioned as shown and reset to zero.
Bring the machine to its no load capacity (boom up)
Record the variation of the instrument
Repeat the test at various angle positions
The maximum value recorded represents the initial clearance of the machine
itself.
Tilting clearance when new
Max. wear
0,8mm
3.2mm
As a general rule, a wear amount higher than 4 times the initial machine clearance
must be approved by Lagendijk Equipment technical department, that is at your full
disposal to estimate the wear condition of your slewing ring.
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7.2 Lubrication / oil type
Equipment
Slewing ring (1)
Grease type
(suitable for temp -20 °C and +120 °C)
AGIP
GRMU EP2
BP
LS-EP2
ESSO
Becom EP2
SHELL
Gadus S2 A320 2
MOBIL
Mobilux EP2
KROON OIL
Multipurpose grease 2
2 rows of 8 nipels
After the first 50 hours of use and then after
every 100 hours of use
The operating of pumping grease should be
carried out while the crane is rotating and should
be considered complete when the grease leaks
from the seal and forms a light film.
Before and after long periods of disuse of the
machine, new grease lubrication should be
carried out.
Number of grease nipples
Interval of lubrication
How to
Additional information
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8. Main hoisting winch gearbox
8.1 Cleaning
Periodically remove dust from the main winch. Do not use solvents or other products
that are incompatible with the construction materials. Do not aim blasts of high
pressure water at the reduction gear.
8.2 Routine maintenance
Routine maintenance is to be carried out by the end user. Maintenance must be
carried out by a person working in compliance with the accident prevention rules so
as to guarantee his safety and that of the other people in the vicinity.
Before starting any maintenance work, make sure the main winch is can’t be
switched on during maintenance work. Therefore wounding person’s working on the
winch. Always use suitable tools, in good conditions to remove and mount
components.
8.3 Extraordinary maintenance
Extraordinary maintenance is the competence of the Lagendijk equipment service,
therefore it is prohibited to open the reduction gear for any type of operation that
does not fall within the category of those defined as “routine maintenance”
Before starting any maintenance work, make certain there is no potentially explosive
atmosphere.
8.4 After the first 100 hours of operation:
- change the oil;
- clean the plugs;
- remove all metal residuals from the magnetic plug, making sure there are no big
fragments; if there are, contact Lagendijk Equipment service;
- check tightness of all the screws.
To change the oil, place a tray underneath in which to collect the waste oil and
unscrew the filling up and draining plugs. Wait a few minutes until all the oil has
drained off and then screw the drain plug back on, replacing the seal. Put the new
oil in (do not mix oils of different brands or properties) up to the level foreseen and
then screw the filling up plug back on, replacing the seal.
Change the oil when the reduction gear is still warm as this makes it easier to empty
the oil completely, avoiding the formation of oil foots.
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8.5 Every 500 hours of operation:
- Visually check the oil level by way of the plugs;
- check the condition of the external seals and make sure there are no leaks. If there
are, replace the seals, using original spare parts;
- check tightness of all the screws.
8.6 Every 1,000 hours of operation:
- check the surface temperature in the area found to be the hottest during the
inspection. The maximum temperature reached must be below 130°C
If the temperature exceeds 130°C stop the machine immediately and contact the
Lagendijk equipment service.
8.7 Every 2,000 hours of operation or at least once every 12 months:
- change the oil;
- clean the plugs;
- check tightness of all the screws.
8.8 Every 5,000 hours of operation:
- replace all the bearings;
- change the external O rings;
- check the extent of wear of all gears.
If anomalies are found with the gears contact the Lagendijk equipment service
8.9 Winch data
• Maximum hoisting pull:
• Hydraulic motor displacement:
• Working pressure:
• Maximum starting pressure:
• Maximum line speed :
• Maximum working flow:
• Minimum working flow:
• Planetary gear reduction ratio:
• Multidisc negative brake, braking static
torque:
• Minimum opening brake pressure:
• Maximum allowable brake pressure:
• Rope storage quantity:
• Maximum pressure with stopped winch,
measured at the distributor exhaust manifold:
• Internal lubrication - quantity:
111.9 kN on1 th layer
108 cc
29.5 MPa (295 bar)
36.8 MPa (368 bar)
36.9 m/min on 3 th layer
160 l/min
10 l/min
1:59
80 daNm
2.7 MPa (27 bar)
30 MPa (300 bar)
75 m of cable Ø20 on 3 layers (DIN 15020)
0.5 MPa (5 bar)
13 kg
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8.10 Lubrication / oil type
Equipment
Winch bearing (10)
Lubrication type
(suitable for temp -20 °C and +120 °C)
AGIP
GRMU EP2
BP
LS-EP2
ESSO
Becom EP2
SHELL
Gadus S2 A320 2
MOBIL
Mobilux EP2
KROON OIL
Multipurpose grease 2
1
After the first 50 hours of use and then after
every 100 hours of use
The operating of pumping grease should be
carried out while the crane is rotating and should
be considered complete when the grease leaks
from the seal and forms a light film.
Before and after long periods of disuse of the
machine, a new bearing lubrication should be
carried out.
Number of grease nipples
Interval of lubrication
How to
Additional information
Equipment
Oil type
(suitable for temp -20 °C and +60 °C)
Oil Quantity
Interval of lubrication
How to
Additional information
Winch gearbox (11)
AGIP
BP
Castrol
Blasia SX 320
Energol GRXP-150
Alphasyn EP 320
Chevron
KLüBER
Mobil
Molikote
SHELL
Texaco
Tegra Synthetic Gear 320
Klübersynth EG 4-320
Mobilgear SHC Gear 320
L-1132
Omala S4 GX 320
Pinnacle EP 320
Total
Carter SH 320
Tribol
1510/320
13 kg
After the first 100 hours of use and then after every
1500-2000 hours of use or every 12 months. Oil
samples can be used to prolong
the intervals between replacing the oil.
The drain and fill plug of the winch are accessible
through the side plates of the winch. Use the filling plug
to fill the oil to the oil level in the middle of the level plug
(level plug in horizontal position).
Before and after long periods of disuse of the machine,
a new oil change or oil sampling should be carried out.
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8.11 Troubleshooting
Should an anomaly occur during operation consult the following table. If the problem
persists, contact Lagendijk equipment
Anomaly
Oil leakage from
the seals
Vibrations and/or
excessive noise
The stationing
brake fails to
disengage
Over-heating
With motor
activated the
reduction gear
does not rotate
Stationing brake
does not block
Possible cause
Hardening of seals due to
prolonged storing
Seals damaged or worn
Reduction gear not installed
correctly
Internal anomaly
Lack of oil
Disks stuck due to the period of
stationing.
Brake seals faulty
Lack of oil
The brake does not completely
open
High thermal power
Incorreect mounting of motor
solution
Clean the area and check
for leakage after a few
hours of operation
Contact Lagendijk
Check the fixing
Contact Lagendijk
Check the brake
conection
Apply pressure and put
the brake inlet in rotation.
Contact Lagendijk
Add oil
Check opening pressure
Brake blocked
Contact Lagendijk
Check coupling between
motor and reduction gear
Check the braking system
Internal anomaly
Contact Lagendijk
Residual pressure in the circuit
Check hydraulic circuit
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9. CABLE
9.1 Cable inspection
The winch cables must be inspected monthly for wear and tear. It is impossible to
provide an exhaustive list of all the kinds of mechanical damage that a wire rope can
suffer throughout its service life. For this reason, the following list should only be
regarded as a general guide.
None of the kinds of damage described can be repaired. Never-the less, their
importance rages from superficial damage to total destruction. If you are in any doubt
as to importance of the damage, remove and replace the wire rope immediately and
contact us for technical support or advice




Check the condition of the cable carefully, along its en-tire length. If it has any
dents, crushed sections, bulges or a number of broken strands, it must be
replaced with a cable of the same specifications and length.
Replace the cable when its nominal diameter has re-duced by 10 % due to
wear or the elementary strands breaking.
Replace the cable when corrosion or any kind of warp-ing occurs.
Replace the cable when the lead coating on the cable lug is damaged.
1. Birdcaging (six-strand wire rope) caused by shocks while under load
2. Steel wire rope that jumped out of the pulley
3. Birdcaging (rotation-resistant wire rope) caused by wear on the pulleys
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4. Birdcaging resulting from jamming while passing through a pulley
5. Shock while working under load, a torque created during installation, jamming
while passing through a pulley, or the wrong rope has been selected for the
application.
6. Multiple layers on the drum: layer crushed by layer above
7. Slack spooling on the drum : friction between successive wraps \
8. Slack spooling on the drum : wire rope is crushed at the crossover zone
Inspect the wire rope terminations, looking for broken wires at the base of sockets or
ferrules. Examine the terminations for traces of corrosion, deformation and cracking,
following the inspection procedures laid down by the manufacture.
NEVER ATTEMT TO REPAIR A WIRE ROPE TERMINATION YOURSELF
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9.2 Cable lubrication
The wire ropes are lubricated during production. The type and the quantity of
lubricant used depends on the wire rope construction and its intended use. The
factory lubrication during manufacture gives the wire rope enough protection for
storage.
After this, the lubrication process must be repeated at regular intervals.
In all cases, the service life of the wire rope will be significantly reduced unless you
plan a lubrication programme (1x a week).
Relubricating wire rope is not always an easy job. Apart from the fact that the
lubricant itself is a messy product, applying the lubricant effectively can be
complicated by existing deposits on the wire rope (old lubricant, dirt, various
particles, etc.) preventing the lubricant penetrating to the wire rope core. In this
situation, you will either have to clean the wire rope thoroughly before starting, or
else use a high-pressure lubrication process to “force” the lubricant into the wire rope
core.
If the wire rope being relubricated is clean, you can use special lubrication sprays
that can penetrate the wire rope. The lubrication method and the type of lubricant
depend on the length, diameter and construction of the wire rope being lubricated,
and also on the equipment the wire rope will be attached to.
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Equipment
Wire Rope (11)
Lubrication type
(suitable for temp -20 °C and +120 °C)
KROON OIL
Multipurpose grease 2
SHELL
Gadus S2 A320 2
AGIP
Precis
Nyrosten
Nyrosten T55
n.a.
Every 4 weeks
Grease is normally applied on to the wire rope by
using a brush. An alternative is to use a lubricant
that can be sprayed on the wire rope.
A shorter working life of the of the rope will result
from lack of maintenance, particularly if the
crane is used in a corrosive environment.
Number of grease nipples
Interval of lubrication
How to
Additional information
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9.3 Installing the winch cable with a thimble
Attention:
The winding direction of the cable must be the same as the drum rotation direction
shown by the arrow. Ensure that the emergency switch is working and that a skilled
operator is on hand and ready to stop the winch in the event of entangling or other
irregularities that could cause harm to the operator in the vicinity of the cable.
If the cable is not sufficiently compact during the initial mounting phase, it may get
caught up in the coils underneath and damaged when load is applied to it.
1) Place the end of the cable into the slot on the drum and then into the pocket “A”.
2) Fold the cable around the thimble “B”. Then secure the cable and thimble in the
Slot by pulling firmly.
9.4 Installing the winch cable with clamps
If the cable is not sufficiently compact during the initial mounting phase, it may get
caught up in the coils underneath and damaged when load is applied to it.
1) Place the end of the cable in the slot on the edge of the drum and then into the
clamps “A”. The protrusion “B” from the final clamp must be at least twice the
diameter of the cable.
2) Tighten the clamp screws by the same amount.
For the cable to wind correctly, a preload of 5 % of the cable’s breaking load is required.
The breaking load varies depending on the cable’s diameter and type, and must be
Indicated by the supplier on the cable’s certificate.
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9.5 Start-up information after installing new cable
Safety instructions

Check the condition of the lifting parts (cable, hook, etc.) before using the
winch.

When carrying out start-up operations, the operator and any other team
members must remain a safe distance from the cable, to avoid injury in the
event of it breaking.

The first few lifting operations should be carried out with a modest load no
more than 1 meter from the ground, to check that the lowering operation is
controlled.

Carry out manoeuvres gradually, avoiding sudden movements and swinging.

Bring the winch to its limit position and gently push the distributor lever to
purge any air from the system.
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10. Pulleys and drums
10.1 Inspection of pulleys and drums
Careful maintenance of the equipment on which the wire rope is used has significant
impact on its service life. Poorly-aligned sheaves, worn grooves, worn sections
creating shocks while under load or excessive vibrations will all inevitably impair the
service life of the wire rope.
The sheaves grooves must be inspected monthly in order to detect wear that may
cause jamming, abrasion or birdcaging. If the groove shows signs of an impression
of the wire rope construction, the pulley must be replaced or else remachined and
requenched. The same applies to the drums if they show similar impressions.
10.2 Measuring the groove radius
When inspecting the sheaves, your first task is to check the conditions of the
grooves. You will need to use a radius gauge to check the dimensions, contour and
extent of wear of the groove.
Two types of radius gauge are normally used, which differ in terms of the percentage
by which they are larger than the nominal diameter of the wire rope in question.
When inspecting new or remachined pulleys, and in order to ascertain the correct
wire rope to use, you should use a radius gauge 1% larger than the maximum
tolerance of the wire rope diameter-in other words, the sheave groove must measure
1% more than the effective diameter of the wire rope.
Many radius gauges available on the market are of the type “NO-GO” and are
manufactured with a tolerance of + 0.5% in relation to the maximum tolerance of the
wire rope diameter. When using these NO-GO gauges, always make sure that the
effective diameter of the wire rope is less than the diameter of the gauge.
If a wire rope passes through slightly undersized pulleys, it will deteriorate more
quickly and birdcaging may result.
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Check the flanges for wear
Check for wear in the sheave
grooves.
Check the bushings for buckling,
lubrication and verify that the
sheave rotates freely
10.3 Pulleys Data
We recommend the use of pulleys made of steel or cast steel in the trolley.
The other pulleys may be made of plastic (PA6)

Groove diameter
Minimum 0.53 to 0.535 x d
Maximum 0.55x d
Recommended: +/- 1% of effective diameter of wire rope

Groove depth
Recommended: 1.5 x d or d x √ -2

Groove angle
Minimum
: 45°
Maximum
: 52°
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11. Correct spooling procedure on a drum
In multilayer drums, a wire rope is subject to wear at the cross-over zones from one
layer to the next. At these points, the wire rope is subject to considerable abrasion
and to crushing as it passes over the grooves formed by the wire rope as it starts
running over the lower layer.
When the wire rope is unspooled you can clearly hear the sound of rubbing. To
ameliorate this problem and optimise the service life of the wire rope, you are
advised to cut off a length of wire rope at the anchor point on the drum-shorten the
wire rope by approximately 1/3 of the drum circumference.
This has the effect of shifting the crossover zone to another section of the wire rope,
causing the working load to be carried by a section of wire rope that is not already
subject to friction and crushing.
These are the crossover zones where the wire rope can be damaged initially.
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12. Hydraulic
12.1 lines and hoses
Hydraulic lines, hoses and fittings may never be repaired ! any damaged sections
must be replaced immediately.
Even when hoses and lines are installed, stored and used according to specification
– they undergo a natural aging process. For that reason, their service life is limited.
Improper storage, mechanical damage and improper use are the most frequent
causes of hose fractures.
 Use original spare parts according to manufacturers specification.
 The service life of a hydraulic hose may not exceed 6 years.
12.2 Replacement and inspection
Hoses and lines must be replaced if any of the following points are found during an
inspection :
-
Damage on the external layer into the inner layer ( such as chaffing cuts and
rips)
- Brittleness of the outer layer (crack formation of the hose material)
- Change in shape which differ from the natural shape of hase or line, when
under pressure or when not pressurized, or in bends and curves – such as
separation of layer, blister or bubble formation.
- Leakages
- Non observance of installation requirements
- Damage or deformation of hose fittings, wich might reduce the strengths of
the fitting or the connection between hose and fitting
- Any movement of the hose away from the fitting
- Corrosion on fittings, which might reduce the function or strength of the fitting
- Storage or service life has been exceeded.
Prior to installation and start-up, please carfully read the following set of guidelines :
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12.3 Oil : Good quality mineral oils offering a high viscosity index (above 150)
containing antioxidant and antifriction additives in compliance with DIN 51524 and
DIN 51535, more specifically oils pertaining to the H-LP group in accordance with
DIN 51535-2
Ambient temperature
+ 10° to + 30°C
- 10° to + 20°C
+ 20° to + 40°C
Viscosity
ISO VG 46
ISO VG 32
ISO VG 68
If different ambient temperatures exist or different types of oil are used, pleas contact
Lagendijk Equipment.
12.4 Maintenance : Start-up is expected to take place one month following the date
of delivery ; if not, Lagendijk Equipment should be advised thereof in writing one day
at the latest following start-up, all filters must be replaced.
Six months after start-up, all filters must be replaced once again. After that, every
twelfth months following the previous replacement round, all filters must be replaced.
Please note : only original filters are to be used. During the warranty term,filters must
be ordered form Lagendijk Equipement enabling us to make sure that the filters are
being replaced.
12.5 Regular maintenance : Oil levels and oil temperature are paramount factors
(anywhere between 40 an 50°C is perfect; avoid temperatures up to and in excess of
60°C; at 80°C, switch off the unit and contact Lagendijk Equipment. The oil analysis
serves to determine whether or not the oil needs changing, with filter replacement
interval possibly needing to be adjusted accordingly.
12.6 Filters : After the filters have been repaced and the unit has been operational
for a couple of hours, an oil sample is to be taken for chemical analysis and a
particle count at an approbated laboratory. It is this oil analysis which serves to
determine whether or not the filter replacement interval needs adjusting. Maintance
duties should strictly be preformed by qualiied staff, i.e. “hydraulics engineers” to be
precise.
Failure to observe filter replacements intervals will result in the termination of the
warranty. Analysis results of oil samples taken during the warranty term are to be
forwarded to Lagendijk Equipment. Failure to comply with these requirements forfeits
the warranty. If your enterprise does not have qualified staff of its own, Lagendijk
Equipment is happy to offer you this service. We cannot accept liability for any
components which have not been supplied by Lagendijk Equipment or any work
preformed by non-Lagendijk engineers. Please bear in mind that the use of nonLagendijk approved components (including pipings) may seriously damage the
system.
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12.7 Viscosity : The viscosity of the oil is important for its performance. It depends
very much on the working conditions (e.g. temprature) and the time the oil has been
in use. A viscodity change of 10% is considered abnormal
12.8 Oil condition index (OCI) The OCI is a measure of the conductivity of the oil. It
indecates the concentration of soot and other conducting materials present in the
sample, e.g. water and metal particles. An arbitrary scal of 0-40 is used. A value of
10-12 is typical of new oils and values up to 28 are typical of used oils in good
condition. Higher values indicate a problem may exist. Again to establish the cause
of an increase in the OCI value, other tests must be carries out.
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Summary perpetual inspection and testing
Working
hours
Date
By
Remark, taken off/repaired
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Summary perpetual inspection and testing
Working
hours
Date
By
Remark, taken off/repaired
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13. Service
Once a year there should be a visual inspection to check the condition of the crane
Every 10 years an authorized and independent testing company must inspect the
crane.
CONTACT THE SUPPLIER IMMEDIATELY WHEN A PROBLEM OCCOURS.
SAFETY COMES FIRST!
If a third party makes any changes without written approval of the supplier, the
supplier can’t take any responsibility.
For service, reparation and maintenance you can always reach us at:
Choorhoekseweg 3 4424NW Wemeldinge the Netherlands
Tel. +31 (0) 113 – 621 385 Fax. +31 (0) 113 – 622 591
Website
E-mail
: www.lagendijkequipment.com
: info@lagendijkequipment.com
You can reach us day and night on the same number.
14. Disposal installation
When the installation is going to be disposed, a specialized company has to advise,
where the diverse materials should be disposed.
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