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Maintenance Manual for Crawler Crane
4.7.5 Inspection of hoisting winch reducer and derricking winch reducer
Both hoisting winch reducer and derricking winch reducer are designed using integrated
planetary gears. The gears are designed for long service life and the drive shaft and drive
gear are rated for endurance. Even though these gears are designed for long service life,
an external visual inspection is not adequate, since their life can be significantly affected by
bad maintenance (insufficient oil), defective seals, improper operation or overuse. The
inspection must therefore be carried out by a competent inspector in accordance with the
following guidelines.
a) Inspection interval
Every 1000 operating hours, at least once a year
b) Check oil level
For hoisting and derricking winches, we recommend that the oil be drained and the
amount compared to the specified oil quantity.
c) Check oil color
If the oil is block and/or a burnt oil smell is detected, you can judge that the oil has been
overheated. In this case, the oil must be changed at once.
d) Check for foreign substances
This inspection should be carried out in a qualified laboratory. The used oil shall be
dribbled onto the specified filter medium. The oil sample is visually checked under a
microscope for foreign particles. If any particles are detected, the oil must then be sent
to a qualified laboratory and analyzed to determine the makeup of the particles.
e)
Evaluation of foreign substances found in the oil
The maximum permissible quantity of foreign material measured by weight is 0.15%
of total oil weight.
Maximum permissible foreign particle size from fine abrasion is 0.229mm.
If above values are exceeded, the drive device must be dismantled to determine the
root cause of increased contamination and then the drive device should be refilled
with fresh oil.
These inspections must be carried out by professionals.
f) Visual inspection
The drive devices shall be checked for leakage, since any loss of oil, in addition to
polluting the environment, can lead to gearbox failure. When checking the crane every
year, make sure the used theoretical service life of winches. If necessary, the crane
operator must ask professionals to do the job.
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