Scheduled maintenanceReports I = Maintenance interval 500h, Reports II = Inspections, checks and etc.interval 500h (Cummins diesel)

Kalmar RTG8 wheels

NOTE! IF 5000 DIESEL OPERATING HOURS IS NOT REACHED DURING ONE YEAR’S INTERVAL, THE SCHEDULEDMAINTENANCE OF 5000H IS PERFORMED DURING THE YEARLY MAINTENANCE.5000 HOUR SERVICE PROSEDURES ONLY APPLY TO THOSE MARKED WITH AN X.

Maintenance item Note Reference

500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 Yearly6500 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500 12000

12500 13000 13500 14000 14500 15000 15500 16000 16500 17000 17500 1800018500 19000 19500 20000 20500 21000 21500 22000 22500 23000 23500 2400024500 25000 25500 26000 26500 27000 27500 28000 28500 29000 29500 30000

Main engine (Cummins Diesel)

1 Steam clean engine x

2 Change engine oil x x x x x x x x x x x x xSee Maintenance manual section 1 Engine, 1.8 Lubrication

3 Change engine filter(s) x x x x x x x x x x x x xSee Maintenance manual section 1 Engine, 1.8 Lubrication

4 Change fuel filter(s) x x x x xSee Maintenance manual section 1 Engine, 1.2 Fuel system

5 Clean fuel filter(s) (if using Spin-On Type) x x x x x

See Maintenance manual section 1 Engine, 1.2 Fuel system

6Change air filters (2pcs)when red indicator flag is at the raised position

x xSee Maintenance manual section 1 Engine, 1.6 Air intake/exhaust outlet

7 Empty dust collector of air filter x x x x x x xSee Maintenance manual section 1 Engine, 1.6 Air intake/exhaust outlet

8 Change coolant filter(s) if in use x x x x xSee Maintenance manual section 1 Engine, 1.7 Cooling system

9 Clean breather tube x xSee Maintenance manual section 1 Engine, 1.6 Air intake/exhaust outlet

10 Adjust valves and injectors x x xSee Maintenance manual section 1 Engine, 1.5 Mechanical parts

11 Tighten mounting bolts x x x x x xSee Maintenance manual section F Technical data Tightening torques

12 Clean and flush cooling system xSee Maintenance manual section 1 Engine, 1.7 Cooling system

Wheel hubs, driven and non driven wheel

13 Change oil x1) x1) First oil change and first fork housing cleaning 100 operating hours.

See Maintenance manual section 3 Driveline/axle, 3.3 Lubrication points.

14 Lubricate cardan shaft and lower bearing x x x

See Maintenance manual section 3 Driveline/Axle, 3.3 Adjusting a wheel bearing and lubrication

A Maintenance report, maintenance interval 500h

Maintenance item Note Reference

500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 Yearly6500 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500 12000

12500 13000 13500 14000 14500 15000 15500 16000 16500 17000 17500 1800018500 19000 19500 20000 20500 21000 21500 22000 22500 23000 23500 2400024500 25000 25500 26000 26500 27000 27500 28000 28500 29000 29500 30000

A Maintenance report, maintenance interval 500h

15 Adjust wheel bearings x

See Maintenance manual section 3 Driveline/Axle, 3.3 Adjusting a wheel bearingand lubrication

Steering gear brake motor

16 Change oil x1) 1) First oil change and first gear housing cleaning

See Maintenance manual section 5 Steering, 5.2 Lubrications points

17 Clean gear housing x18 Clean breather plug x

19 Carry out complete inspection of gear x

20 Brake inspection and maintenance x

See Maintenance manual section 4 Brakes, 4.3 Checking and adjusting the steering brake

Trolley motor

21 Lubricate bearings x x x xSee Maintenance manual section 7 Load handling, 7.2 Lubrication points

Trolley gear

22 Change oil x1) x 1) First oil change and first gear housing cleaning

See Maintenance manual section 7 Load handling, 7.11 Lubrication points, trolley

23 Clean gear housing x2) x 2) First oil change and first gear housing cleaning

24 Clean vent plug x x x x25 Lubricate seals, clean nipples x x x x

26 Carry out complete inspection of gear x

Skew geared brake motor

27 Change oil 2) x1)

1) First oil change and then after every 6 years. 2) Oil filled to middle of oil sight glas(1,1l).

See Maintenance manual section 7 Load handling, 7.11 Lubrication trolley skew

28 Lubrication x x x x x xSee Maintenance manual section 7 Load handling, 7.11 Greasing points skew.

29 Clean gear housing x30 Clean breather plug x

31 Carry out complete inspection of gear x

Maintenance item Note Reference

500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 Yearly6500 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500 12000

12500 13000 13500 14000 14500 15000 15500 16000 16500 17000 17500 1800018500 19000 19500 20000 20500 21000 21500 22000 22500 23000 23500 2400024500 25000 25500 26000 26500 27000 27500 28000 28500 29000 29500 30000

A Maintenance report, maintenance interval 500h

32 Brake inspection and maintenance x x x

See Maintenance manual section 4 Brakes, 4.3 Checking and adjusting the skew brake

Trim geared brake motor (option)

33 Change oil x

See Maintenance manual section 7 Load handling, 7.2 Performing the trim maintenance

34 Lubrication x x x See load handling section 7, Greasing points trim.

35 Clean gear housing x36 Clean breather plug x

37 Carry out complete inspection of gear x

38 Brake inspection and maintenance x x

See Maintenance manual section 4 Brakes, 4.3 Checking and adjusting the trim brake

Hoist motor

39 Lubricate bearings x xSee Maintenance manual section 7 Load handling, 7.2 Lubrication points

Hoist brake

40 Static brake test SWL (rated load) x 1) See test from Brake Operating manual. Supplier documentation

Hoist emergency brake (option) (holding brake)

41 Change oil x 1) See from Brake Operating manual Supplier documentation

42 Bleeding of the brake and release (open) the brakes hydraulically x 1) See from Brake Operating

manual Supplier documentation

Hoist gear

43 Change oil x1) 1) First oil change and first gear housing cleaning

See Maintenance manual section 7 Load handling, 7.11 Lubrication hoist gear

44 Clean gear housing x1) 1) First oil change and first gear housing cleaning

45 Clean breather plug x x x x

46 Lubricate seals, clean nipples x xSee Maintenance manual section 7 Load handling, 7.11 Lubrication hoist gear

47 Carry out complete inspection of gear x

Maintenance item Note Reference

500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 Yearly6500 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500 12000

12500 13000 13500 14000 14500 15000 15500 16000 16500 17000 17500 1800018500 19000 19500 20000 20500 21000 21500 22000 22500 23000 23500 2400024500 25000 25500 26000 26500 27000 27500 28000 28500 29000 29500 30000

A Maintenance report, maintenance interval 500h

Hoist ropes

48 Grease the ropes 1) x x x x x x

1)Depending on climatic conditions, chain lubricationinterval may be extended to 2 months. Spread mineral oil (Engine oil 10W/Dieseloil CD10W) with a brush.

Lubrication

49 Lubrication 1) x x x

1)Lubrication must be performed regulary avoiding use of too muchlubricant at the same time. (Greasing: e.g.Multipurpose grease, Beacon EP/2). Some greasing points have shorter lubrication intervals: See maintenanse manual.

Frame and shields tightening torque

50 Tightening, most important screws and bolts x x x

See Maintenance manual section 7 Load handling, 7.2 Tightening torques

Spreader (Bromma)

51 Lubrication 1)

1)Note: After 50 and 300 hours Lubricate and check the various points as per the lubrication instructions

See Bromma BGS Manual, 6.1 Periodic maintenance procedures

Spreader,Twistlocks

52 Tighten, check function 1) 1)Note: After 100 hoursSee Bromma BGS Manual, 6.1 Periodic maintenance procedures

53 Dismantle, inspect, perform crack detection x x

See Bromma BGS Manual, 6.1 Periodic maintenance procedures

54 Replace pins and spherical washers x

See Bromma BGS Manual, 6.1 Periodic maintenance procedures

Spreader,Glide plates

55 x 1)Note: Minimum thickness 17mm

See Bromma BGS Manual, 6.1 Periodic maintenance procedures

Maintenance item Note ReferenceDaily 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 Yearly

6500 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500 1200012500 13000 13500 14000 14500 15000 15500 16000 16500 17000 17500 1800018500 19000 19500 20000 20500 21000 21500 22000 22500 23000 23500 2400024500 25000 25500 26000 26500 27000 27500 28000 28500 29000 29500 30000

Main engine (Cummins Diesel

1 Check air system cleaners, indicator x See Maintenance manual section 1

Engine, 1.6 Air intake / exhaust outlet

2 Check oil level x x x x x x x x x x x x x See Maintenance manual section 1 Engine, 1.8 Lubrication

3 Check coolant level x x x x x x x x x x x x x See Maintenance manual section 1 Engine, 1.7 Cooling system

4 Drain water and sediment from fuel-water separator x x x x x x See Maintenance manual section 1

Engine, 1.2 Fuel system

5 Check fan belt tension x x x x x x x x x x x x x See Maintenance manual section 1 Engine, 1.6 Air intake / exhaust outlet

6 Check fuel, oil, coolant leaks (repair) x

7 Check condition of battery x x x x x x x x x x x x

8 Check the fan hub bearing clearance x See Maintenance manual section 1

Engine, 1.6 Air intake / exhaust outlet

9 Inspect turbo charger x x

10 Inspect vibration damper mounting x x See Maintenance manual section 1

Engine, 1.6 Air intake / exhaust outlet

11 Inspect idler pulley assembly x12 Inspect water pump x

Wheel hubs, driven and non driven wheel

13 Check oil level x x x x x x x x x x x xSee Maintenance manual section 3 Driveline/axle, 3.3 and 3.4 Driven wheel / Non-driven wheel

14 Check wheel nuts tightening torque x x x x x x x x x x x x

See Maintenance manual section 6 Suspension, 6.3.3 Tightening toques of the wheel nuts

Steering geared brake motor

15 Check gear unit function xSee Maintenance manual section 5 Steering, 5.2.4 Checking the wheel alignment

16 Check oil level / Gear unit for leakage x x

See Maintenance manual section 5 Steering, 5.2.3 Filling/ Changing planetary gear oil

17 Check all fixing screws for tightness 1) x

1) Check all fixing screws for tightness after first oil change and then after every year

18 Check air gap of the brake and adjust when needed x x

See Maintenance manual section 4 Brakes, 4.3 Checking and adjusting the steering brake

B Maintenance reports, inspections, checks and etc; maintenance interval 500h

Maintenance item Note ReferenceDaily 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 Yearly

6500 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500 1200012500 13000 13500 14000 14500 15000 15500 16000 16500 17000 17500 1800018500 19000 19500 20000 20500 21000 21500 22000 22500 23000 23500 2400024500 25000 25500 26000 26500 27000 27500 28000 28500 29000 29500 30000

B Maintenance reports, inspections, checks and etc; maintenance interval 500h

Gantry brake motor

19

Check during operation that running smoothness of machine and running noise of bearings have not deteriorated

x x

20Check during standstill that no subsidence or cracks have occurred in the foundation

x x

21 Check air gap of the brake and adjust when needed x x x x x x

See Maintenance manual section 4 Brakes, 4.3 Checking and adjusting the gantry brake

22 Check tightness of all fixing bolts of mechanical and electrical joints x

Trolley gear23 Check gear unit noise x

24 Check oil level xSee Maintenance manual section 7 Load handling, 7.11 Lubrication pointstrolley gear

25 Check oil temperature x

26 Check gear unit for leakage x

27 Check gear unit for leakage x x x x

28 Check all fixing screws of cardan shaft x x x x

Trolley motor

29

Check during operation that running smoothness of machine and running noise of bearings have not deteriorated

x x

30Check during standstill that no subsidence or cracks have occurred in the foundation

x x

31 Check air gap of the brake and adjust when needed x

See Maintenance manual section 4 Brakes, 4.3 Checking and adjusting the trolley brake

32 Check tightness of all fixing bolts of mechanical and electrical joints x

Skew geared brake motor

33 Check gear unit noise x x

34 Check oil level / Gear unit for leakage x x

See Maintenance manual section 7 Load handling, 7.11 Lubrication pointsskew gear

Maintenance item Note ReferenceDaily 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 Yearly

6500 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500 1200012500 13000 13500 14000 14500 15000 15500 16000 16500 17000 17500 1800018500 19000 19500 20000 20500 21000 21500 22000 22500 23000 23500 2400024500 25000 25500 26000 26500 27000 27500 28000 28500 29000 29500 30000

B Maintenance reports, inspections, checks and etc; maintenance interval 500h

35 Check all fixing screws for tightness 1) x

1) Check all fixing screws for tightness after first oil change and then after every year

36 Check air gap of the brake and adjust when needed x

See Maintenance manual section 4 Brakes, 4.3 Checking and adjusting the skew brake

37 Check bearings 2) 2) Check and if needed change bearings after every 6 year

38 Check lenght of chain xSee Maintenance manual section 7 Load handling, 7.11 Installation instruction for skew pulling device

Trim geared brake motor (option)

39 Check gear unit function

40 Check oil level / Gear unit for leakage 1) x x 1) See operating instruction

41 Check all fixing screws for tightness 2) x 2) Check all fixing screws for

tightness

42Check air gap of the brake and adjust whenneeded 3)

x x

3) If the brake microswitch sends an alarm to the display panel inthe cabin, the brake must be checked and possibly adjusted, or the brake pads must be replaced. Brake pad clearance = 0.3mm. (Note! The microswitch disables the operation of the brakes the clearancehas increased 2.5-fold =0.75mm)

See Maintenance manual section 4 Brakes, 4.3 Checking and adjusting the trim brake

43Check sensors for trim turnin and adjust ifneeded

xSee Maintenance manual section 7 Load handling, 7.2 Hoist ropes, trim sensors

Hoist gear44 Check gear unit noise x

45 Check oil temperature 1) x 1) Inspect from gear's temperature gauge

46 Check gear unit for leakage x

47 Check all fixing screws for tightness x

Hoist brake

48 Check overall function of the brake/brake system x x x x x x Supplier documentation

49 Check brake shoe x x x x x x Supplier documentation

50 Check lining wear / lining thickness x x x x x x Supplier documentation

51 Check condition of the brake disk x x x x x x Supplier documentation

Maintenance item Note ReferenceDaily 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 Yearly

6500 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500 1200012500 13000 13500 14000 14500 15000 15500 16000 16500 17000 17500 1800018500 19000 19500 20000 20500 21000 21500 22000 22500 23000 23500 2400024500 25000 25500 26000 26500 27000 27500 28000 28500 29000 29500 30000

B Maintenance reports, inspections, checks and etc; maintenance interval 500h

52 Check actuator reserve stroke x x x x x x Supplier documentation

53 Check easy mobility of the brake linkage x x x x x x Supplier documentation

54 Check brake spring tension (braking torque) x x x x x x Supplier documentation

55Check adjustment of limit switches and handrelease devices

x x x x x x Supplier documentation

56 Check cleaness an function of the taper key x x x x x x Supplier documentation

57Check possible wear of the automatic wearcompensator

x x x x x x Supplier documentation

Hoist emergency brake (option)(holding brake)

58 Clean off the brake pads/brake disk x x x x x x Supplier documentation

59 Check easy mobility of the brake linkage x x x x x x Supplier documentation

60 Check actuator reserve stroke x x x x x x Supplier documentation

61 Check condition of the brake disk x x x x x x Supplier documentation

62 Check brake shoe x x x x x x Supplier documentation

63 Check hydraulic oil/hydraulic system x x x x x x Supplier documentation

Hoist motor

64

Check during operation that specified technical data are met (power input, temperatures of windings, bearings, coolants, etc.)

x1) 1) First check 500 operating hours.

65

Check during operation that running smoothness of machine and running noise of bearings have not deteriorated

x1) 1) First check 500 operating hours.

66Check during standstill that no subsidence or cracks have occurred in the foundation

x1) 1) First check 500 operating hours.

67Check that alignment of machines is withinpermissible tolerances

x

68 Check tightness of all fixing bolts of mechanical and electrical joints x

69Check that insulation resistance ofwindings issatisfactory

x

Maintenance item Note ReferenceDaily 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 Yearly

6500 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500 1200012500 13000 13500 14000 14500 15000 15500 16000 16500 17000 17500 1800018500 19000 19500 20000 20500 21000 21500 22000 22500 23000 23500 2400024500 25000 25500 26000 26500 27000 27500 28000 28500 29000 29500 30000

B Maintenance reports, inspections, checks and etc; maintenance interval 500h

70 Check that no bearing insulation isshort-circuited x

71

Check that cables and insulating parts (as far as accessible) are in proper condition and show no signs of discolouration 1)

x 1) First check 500 operating hours.

Hoist ropes

72Check ropes for possible damage and changein shape

x

73

Check the ropes at full lenght paying special attention to the following: terminal points; section that goes over the pulley; section straight above the balancing wheel.

x x x x x x

Headblock (option)

74

Inspection of the twistlocks of headblock using liquid penetrant or magnetic particle examination 1)

x1) First inspection shall be carried outafter first 5000 hours or 2 years whichever occurs first.

See Maintenance manual section 7 Load handling, 7.9 Load carrying

Spreader (Bromma)

75

Twistlock: Check the nut and the floating mechanismand ensure that all parts are properly tightened down.Check that the twistlock pin can be moved easily andthat it indicates the correct position (see Adjustingthe twistlock pin).1)

x 1)Note: Every 100 working hours See Bromma BGS Manual, 6.1 Periodic maintenance procedures

Spreader, plates

76 Check x See Bromma BGS Manual, 6.1 Periodic maintenance procedures

Spreader, Telescoping system

77 Check chain tension 2) 2)Note: Every 300 working hours See Bromma BGS Manual, 6.1 Periodic maintenance procedures

Maintenance item Note ReferenceDaily 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 Yearly

6500 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500 1200012500 13000 13500 14000 14500 15000 15500 16000 16500 17000 17500 1800018500 19000 19500 20000 20500 21000 21500 22000 22500 23000 23500 2400024500 25000 25500 26000 26500 27000 27500 28000 28500 29000 29500 30000

B Maintenance reports, inspections, checks and etc; maintenance interval 500h

78 Check chain elongation 3) x x3)Note: Renew chain and gears when max trimming allowance is achieved

See Bromma BGS Manual, 6.1 Periodic maintenance procedures

79 Check gears x x See Bromma BGS Manual, 6.1 Periodic maintenance procedures

80 Check and clean position sensors 4) x

4)Note: Every 100 working hours Renew chain and gears when max trimming allowance is achieved

See Bromma BGS Manual, 6.1 Periodic maintenance procedures

Frame

81 Check trolley frame weldings x

82

Check all weldings of the main crossbeams from the centre to distance of 3,5 m includingrun rails

x

83 Check weldings of the flange of the pivot arm x

84Check weldings of the lower end of the vertical column to height of 1,5m from the sill beam.

x

85 Check and tighten the bolt and screw connection x

Frame

86 Check PLC wiring in driver’s cabin1) x

1)PLC wiring’s fastening should be checked twice a year from the hole under the seat. Seat can be tilted by opening locking bolts at the front of the base of the seat.