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Liebherr CBW crane - Removal of Luffing Cylinders for Overhauling /Renewal of all pivot pins, bearings, bush and covers

ALATAS Middle East was called by ships owner HAMMONIA REEDEREI GmbH to attend the Vessel HR. MARGARETHA at Dubai Maritime City with 3 sets of Liebherr CBW ships crane to carry out removal of all luffing cylinders for Overhauling and to renew all pivot pins, bearings and bush sets.

The Scope of job included the following:

• Job site visit / meeting with Captain, Chief Engineer and discussed about tools, Materials, and Manpower required for the job.
• Mobilization of Manpower, Tools and materials.
• Erection of scaffolding for safe access to crane cylinders and pivot area.
• Rigging and securing the luffing cylinder by belt slings and chain blocks.
• Removal & installation of luffing cylinder pins, bearings and rigging down hydraulic cylinders.
• Major Overhauling & pressure test of all 6 luffing cylinders at Alatas workshop ( Piston rod chroming, new seal kits, barrel honning, build up and machining of cylinder eye ).
• All pivot pin and bearings are seized it requires gouging and cutting of pins enable to pull out
• Renewal of hydraulic hoses for luffing cylinders.
• Crane function test and safety device test.
• Crane load test with GL surveyor.
• Crane hand over.

 
Vessel with 3 Liebherr CBW 60 40/16 (28)S CRANES
Vessel with 3 Liebherr CBW 60 40/16 (28)S CRANES
Liebherr CBW cranes
Liebherr CBW cranes
       
Erection of scaffolding from deck up to luffing cylinder and pivot area
Erection of scaffolding from deck up to luffing cylinder and pivot area
Check of shipboard spares
Check of shipboard spares
       
Check of shipboard spares
Check of shipboard spares
Securing luffing cylinders with chain blocks
Securing luffing cylinders with chain blocks
       
Securing luffing cylinders with chain blocks

Openning the pin cover all screw heads are broken

Pivot pin corroded almost welded by rust in the eye

Rusty and corroded condition of pivot pins

       

Disconnect hoses and plug fittings

Pulling the pivot pin with 120 ton hydraulic jack

Gouging and cutting of pivot pin enable to pull out
Gouging and cutting of pivot pin enable to pull out
       

Pivot pin after gouging and cutting then pulled out using 120 tons hallow hydraulic jack

Same procedure was done on upper cylinder pivot pins

Pivot bearing and bush totally broken

Pivot bearing and bush totally broken
       

Broken parts of pivot bearing assembly

Luffing cylinders delivered to ALATAS Workshop

ALATAS Workshop dis assembling the cylinders for full inspection

ALATAS Workshop dis assembling the cylinders for full inspection
       

Dismantling of hydraulic cylinders at ALATAS Workshop

Dismantled luffing cylinder parts

Dismantled luffing cylinder parts
Dismantled luffing cylinder parts
       
Dismantled luffing cylinder parts
Machining of cylinder eye
Inspection of cylinder body
Inspection of cylinder inner barrel
       

Deep scratches found on piston rod (requires repair and re chroming)

Deep scratches found on piston rod (requires repair and re chroming)

Sratches found inside gland nut

Assembling new bearing and bush on board

       

Bearing with bush assembled on board

Cylinders back on board
Cylinders back on board
Cylinders back on board
       

Cleaning and polishing the bearing mounting on crane prior installation of new bearing assembly

Installation of new bearing assembly on crane

Pushing in new bearing assembly using threaded bar and plate

Lower bearing assembly installed and secured with locking plate

       

Upper bearing assembly installed and secured with locking washer

Renew hoses from control block going to cylinders

Renew hoses from control block going to cylinders
Cylinders on board vessel
       
Cylinder rigging

 Installation of newly Overhauled Cylinders on crane

Inspection and allignment of luffing cylinder to bearing assembly

Inspection and allignment of luffing cylinder to bearing assembly
       

Installation of new pivot pin

Installation of new pivot pin

Pivot pin installed

Installation of new pivot pin
       
Installation of new pivot pin

Pivot pin installed and protection cover secured

New hydraulic hoses connected to holding valves

New hydraulic hoses installed

       

Outer hose fittings and connections protected with denso tape

Luffing cylinder installed

Crane Function test and safety devices test prior load testing

Crane overload test
       
Crane overload test
Crane overload test
Crane overload test
Crane overload test
       

 

 

 
 
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