Common issues
- wire rope wear, broken wires or corrosion on luffing and hoist ropes
- sheave and pulley wear or misalignment
- wear in the slew gear/drive
- load cell or limit switch drift affecting SWL cut-out accuracy
- fatigue cracking at boom foot and pedestal welds
- brake wear on hoist/luffing winches
- corrosion of structural steel in the offshore environment
Inspection checklist
- visual inspection of wire ropes for broken wires, corrosion or kinking
- check sheave grooves for wear
- verify load moment indicator and overload cut-out calibration
- inspect boom and pedestal structure for cracks or corrosion
- check hoist and luffing brake holding capacity
- verify limit switches (anti-two-block, slew limits)
- check hydraulic hose and pipe condition for leaks or chafing
- confirm current proof load test certificate
Service intervals
| Wire rope inspection | before each shift/lift, detailed inspection monthly |
|---|
| Wire rope renewal | condition-based per discard criteria for the fitted rope construction/diameter |
|---|
| Proof load test | typically every 4-5 years or per class/flag requirement - confirm against the crane's certificate |
|---|
| LMI/overload system calibration | annually or per maker's manual |
|---|
| Structural NDT inspection | at major survey intervals per class |
|---|
Typical intervals for this design class, not the manufacturer’s figures for your model. The manufacturer’s manual is binding.
Typical wear limits
| Wire rope discard criteria | apply the broken-wire and diameter-reduction limits of ISO 4309 (or equivalent) for the specific rope construction and diameter fitted - do not apply a single figure across rope sizes |
|---|
Ranges are typical for this design class. Always confirm against the manufacturer documentation for your serial number.
Critical spares
- luffing and hoist wire rope sets
- sheave bearings
- brake linings
- load cell/limit switch assemblies
- hydraulic hose sets
Safety
- dropped load from wire rope failure or overload
- structural failure of boom or pedestal from undetected fatigue cracking
- crush/entanglement hazard at winch drums and sheaves
- hydraulic fluid injection injury
- uncontrolled boom lowering on brake failure
Class survey
Deck cranes used for offshore lifting are subject to periodic class/statutory lifting appliance surveys including proof load testing, NDT of critical structural welds, and verification of the overload protection/LMI system; wire rope inspection and renewal records are typically checked.