Terex Port Solutions Service Products

Holistic service from a single source

Holistic service from a single source
Service packages and
outsourcing partners

Crane transport Assembly and

commissioning

General overhauls Professional Crane

Inspections (PCI)
and maintenance
contracts

Terex Port Solutions offers service

for the entire product lifecycle
Upgrades and retrofits

Repairs

Spare parts supply

2
Service Packages
 Tailored Service Packages by
Terex Port Solutions
Customer benefit

Premium
Package

Comfort Repairs

Full service contracts

Package

Basic Maintenance Maintenance

Package
Material
Supply Inspections Inspections Inspections
Agreement

Parts Parts Parts Parts

Value chain

Service Packages 4
 Tailored Service Packages by
Terex Port Solutions

Basic Comfort Premium

Package Package Package
Special solutions Maintenance by Maintenance by
Services provided

in spare parts certified Terex certified Terex

provision technicians technicians
Regular crane Recommendations Terex takes on the
inspections for repair work usual non-scheduled
Emergency Emergency service maintenance tasks
service hotline hotline Emergency service
hotline
Expert feedback Reduced staff costs Maximum cost control
Customer benefits

on maintenance Not necessary to High degree of

status acquire and manage reliability and
Advantages in know-how availability
spare parts Expert feedback for Maximum resale value
procurement high availability Minimum staff costs
Not necessary to
acquire and manage
know-how

Service Packages 5
 Basic Package provides advantages, if
maintenance is performed by the customer

For customers who prefer to maintain their cranes themselves

Extra discount on spare parts and daily rates of service technicians

Annual crane inspections (Basic PCI)

Preferential treatment for

Supply with spare parts with limited availability (e.g. slew ring)
Scheduling of service engineer visits

Unlimited access to emergency Service Hotline, even in future

Preferential treatment
Regular expert feedback on maintenance status
Service Packages 6
 Comfort Package
for regular maintenance by Terex

Maintenance by certified Terex technicians

Work is carried out corresponding to Terexs maintenance instructions

Regular recommendations for repairs

Comfort Package is a precondition for a paid extension

to the warranty term

Reduced staffing costs

Not necessary to acquire and manage know-how
Service Packages 7
 Premium Package
for maximum availability and cost control

Advantages of the Comfort Package

Terex takes on non-scheduled maintenance activities and repairs

Destruction due to these factors is precluded:

Accidents and damage to equipment
Inappropriate use
Failure on the part of the operating organisation to meet obligations (checking
and cleaning instructions)
Lifting gear, such as spreaders, grabs,
Acts of God

Premium Package is a precondition for guaranteed buy-back

Maximum cost control

High degree of reliability and availability
Service Packages 8
Spare Parts
Reliable and safe spare parts management

Life cycle supply of spare parts

Terex Port Solutions and OEM

spare parts

Replacement solutions for parts no

longer manufactured

Spare parts management for spare

parts with limited availability (e.g.
slew ring, luffing cylinder, )

10
High-performance special wire ropes

Short delivery lead-times Special wire ropes

Hoist ropes specially configured for

Wire
each crane individually: Plastic
internal layer
New rope sockets and rope pendants
Threading eye already fitted
3.1 rope certificate to EN 12385-1
Compacted
(Disposable) rope winder outer strands Core Strands in
the core

Two high quality brands available

Diepa well balanced value-for-money
and highest flexibility in diameters
Verope attractive pricing in defined
diameters
Conventional Compacted
strands strands

11
Professional Crane Inspection
 PCI Professional Crane Inspection
Basic PCI

Scope of Supplies and Services Options

Visual inspection of the crane Oil and grease analysis
Functional test of hoist, slewing, luffing Visual steel structure inspection
and travel gear units
Testing of safety functions
Inspection of secondary systems such as
lighting
Detailed inspection report
incl. PCI Certificate
Costs
One expert for two man-days 3,100
Crane inspection by a Terex expert (incl. report)

Crane out of service for the entire inspection

In addition
period
Travel day 1,100
Expected duration of approx. two man-days Travelling costs, hotel, additional
expenses
Options additional

Evaluation of safety and general crane state

PCI Professional Crane Inspection 13

 PCI Professional Crane Inspection
Options for the Basic PCI

Oil and Grease Analysis Visual Steel Structure Inspection

Sampling of
diesel engine oil
hydraulic system oil
hoist reduction gear unit oil
slew reduction gear unit oil
grease in the slew rim
Laboratory examination of samples
Analysis report
Visual inspection of steel structure areas
subject to high loadings
Inspection by an additional expert
Expected duration of approx. two man-days
Report
Costs
Visual steel structure inspection 3,500
(incl. report)

In addition
Travel day 1,100
Costs Travelling costs, hotel, additional
Oil and grease analysis 2,000 expenses
(incl. report)

Findings about the state of non-accessible Easy identification of steel structure

components cracks
PCI Professional Crane Inspection 14
 PCI Professional Crane Inspection
Premium PCI

Scope of Supplies and Services Options

Visual inspection of the crane Determination of theoretical residual lifetime
Functional test of hoist, slewing, luffing and Determination of theoretical residual value
travel gear units
Testing of safety functions
Inspection of secondary systems such as
lighting
Visual inspection of steel structure
Oil and grease analysis
Costs
Detailed inspection report Two experts for four man-days 7,550
incl. PCI Certificate (incl. report)

In addition
Crane inspection by a Terex expert Travel day 1,100
Crane out of service for the entire inspection Travelling costs, hotel, additional
period expenses
Options additional
Expected duration of approx. four man-days

Maximum availability through recommendations for preventative maintenance

PCI Professional Crane Inspection 15

 PCI Professional Crane Inspection
Options for the Premium PCI

Theoretical residual lifetime Theoretical residual value

Read-out and analysis of the crane Determination of the current value of the
history and/or statistics* crane
Calculation of the theoretical remaining Report
service life of the crane
Report

Costs Costs
Theor. residual lifetime 4,000 Theor. residual value 3,000
(incl. report) (incl. report)

*) if applicable

Valuable information prior a planned major Valuable information prior a planned

investment resale of a crane
PCI Professional Crane Inspection 16
PCI Professional Crane Inspection
Report / Certificate

17
Upgrades
Diesel engine replacement for
Terex Gottwald Harbour Cranes

Upgrade for diesel-powered generator

Quotation lead time up to 4 weeks
Replacement of Delivery lead time
Diesel engine MAN D2842 3 months**
Cummins QST30-G5 3 - 4 months**
Generator
Installation time approx. 1 week
Coupling
Water cooler Price range:
Piping MAN 180,000 - 210,000*
Air filter Cummins 190,000 - 230,000*
*) Additional charges for installation work outside
Europe and for particularly complex projects
**) As at September 2009

Reduced operating costs due to reduced diesel consumption

and longer maintenance intervals
Environmentally more compatible due to reduced exhaust gas and noise emissions
19
Diesel engine replacement for
Terex Gottwald Harbour Cranes

Customer: Port of Rauma, Finland

Crane type: HMK 280 E
(year of construction 1998)

March 2009: Unforeseen breakdown of the

diesel engine
Customer opts for the replacement of the entire
diesel generator set, offering this benefits:
Longer maintenance intervals
Lower diesel consumption
Reduced exhaust gas and noise emissions
Short delivery lead-time for entire system
Installation within 5 days
Including test and commissioning

20
Retrofit Industry PC incl. SPC 300 Assembly
Harbour Cranes of Generation Crane 1995

Siemens Slot-PLC and microelectronic

components are no longer available
Repair of defect components is virtually
impossible
Integrated

Replacement solution:
New Industry PC (IPC) incl. SPC 300
assembly
Modification of current S5 control program to Delivery lead time approx. 1 week
new hardware Delivery lead time up to 6 weeks
Pre-commissioning of new components in Installation time approx. 3 days
Dsseldorf
Budget price 25.500
Installation of modified S5 control program
Travelling costs, additional
Compatible with Siemens ET200U, ET200S hotel, expenses
and ET200M modules

Fast and cost-effective alternative to the upgrade of the system to S7

Longer spare part availability
21
Retrofit Control Consoles in Tower Cab
Harbour Cranes of Generation Crane 1995

Microelectronic components (Multiplexer) are no

longer available

Repair of defect components is virtually

impossible

Replacement solution:
New control panels in tower cab
Replacement of microelectronic by solution Quotation lead time approx. 1 week
based on standard components Delivery lead time up to 6 weeks
Installation time approx. 2 days
Installation and test on site
Modification of electric circuit diagrams and Budget price 25.500
spare parts documentation Travelling costs, additional
hotel, expenses

Fast and cost-effective alternative to the upgrade of the system to S7

Longer spare part availability due to standard components
22
Retrofit Propping Controls in Chassis Cab
Harbour Cranes of Generation Crane 1995

Microelectronic components (Multiplexer) are no

longer available
Repair of defect components is virtually
impossible

Replacement solution:
Replacement of propping control panel in chassis
cab
Replacement of microelectronic by solution based on Quotation lead time approx. 1 week
standard components
Delivery lead time up to 6 weeks
Installation and test on site Installation time approx. 3 days
Modification of electric circuit diagrams and spare
parts documentation Budget price 9.500
Travelling costs, additional
Remark: hotel, expenses
Precondition for this module is a new IPC incl.
SPC 300 assembly

Fast and cost-effective alternative to the upgrade of the system to S7

Longer spare part availability due to standard components
23
SLOT-PLC upgrade
For Crane 95 Generation Mobile Harbour Cranes

Siemens SLOT-PLC previously used

is no longer available

Only limited repairs possible

Replacement solution:
Control system stays a Siematic S5 program
Siemens Industrial PC (IPC) for the
visualisation Quotation lead time approx. 1 week
Integrated SLOT-PLC for controller Delivery lead time up to 3 weeks
Keyboard and optical mouse Installation time approx. 3 days
Failsafe flash memory for controller
Price range 23,000 - 25,000
Travelling costs, additional
Hotel, expenses

Faster implementation compared to full upgrade from S5 to S7

Longer availability of spare parts
24
PC104 CoDeSys upgrade
For Generation 4 / Crane 2000 Mobile Harbour Cranes

Formerly used PC104 is

no longer available

Repairs virtually impossible Integrated

Replacement solution slot PLC SPCP-600:

New industry PC (IPC) for visualisation
Integrated CoDeSys slot PLC SPCP-600 for control
Adaptation of the control program to the new
hardware Quotation lead time approx. 1 week
Pre-commissioning of the new hardware in Delivery lead time up to 9 weeks
Dsseldorf Installation time approx. 3 days
Control program unchanged on the basis of
CoDeSys
Price range 24,000 - 26,000
Compatible with Siemens ET200U, ET200S and Travelling costs, additional
ET200M modules
hotel, expenses

Fast and cost-effective alternative to the upgrade of the system to S7

Longer spare part availability
25
Upgrade control system to Siematic S7

Replacement of existing control computer

with S7 PLC 300/400 CPU
Controller program with Simatic S7
S7 components as input / output modules
Networking of modules via Profibus
Options:
Programming unit: Simatic Field PG
Replacement of Simoreg for hoist and Quotation lead time up to 5 weeks
slewing gear Delivery lead time 6 to 7 months
Two new control units in electrics room Installation time 4 to 6 weeks
and tower cab
Price range 180,000 - 230,000*
Replacement of safe load indicator
Travelling costs, additional
Replacement of control levers in Tower Cab hotel, expenses
Replacement of main circuit breaker *) inc. installation in Europe

Modern, powerful computers

Longer availability of spare parts
26
External power supply upgrade for
Terex Gottwald Harbour Cranes

Increased efficiency
Reduction of noise
emissions
No exhaust
emissions in the port
Reduced operating
costs
Less maintenance
cost Quotation lead time up to 4 weeks
Delivery lead time up to 6 months
Installation time 2 to 4 weeks

Price range 140,000 - 220,000

Travelling costs, additional
hotel, expenses
Installation additional

27
Medium voltage external power supply

Motor-driven cable
reel with one cable

Power cable duct

Transformer

Underground quay switch cabinet

Power cable deflection funnel

Alternative: quay power socket

28
690 V external power supply

Motor-driven cable
reel with two cables
Transformer

Power cable on quay surface

Quay switch cabinet

Power cable
deflection funnel

Power plug-in contacts 2 x 690 V power cable

29
 Dynamic brake resistor upgrade

Diesel generator Ancillary Hoist Slewing Luffing Dynamic

consumers gear gear brake resistor

3 ~ AC supplied by
diesel generator

Upgrade:
Replacement of conventional brake
resistors by dynamic brake resistors AC AC AC

DC DC DC
Advantages:
Reduced diesel consumption
Reduced noise emissions due to
constant diesel motor operationAncillary DC DC 3 ~ AC
No black smoke emissions

Dynamic brake resistor upgrade 30

 Dynamic brake resistor upgrade
Power [kW]

0 10 20 30 40 50 60 70 80

Acceleration Deceleration Acceleration

Time [s]

Power demand of the drives Overall power consumption

Power dissipation in conventional resistors Energy saving

Dynamic brake resistor upgrade 31

 Dynamic brake resistor upgrade

Load spectrum typical for

Mobile Harbour Cranes
Loading of mainly
empty containers
Unloading of empty and
full containers
Lifting fruit pallets
out of holds

4,000 operating hours p.a.

Significant diesel savings

Mobile Harbour Crane

G HMK 6407
Capacity: 100 t
Outreach: 51 m
Weight: 420 t
Installed power: 895 kW
Max. hoisting speed:
90 m/min

Dynamic brake resistor upgrade 32

 Dynamic brake resistor upgrade
Services included

Adaptation of control program by

engineers in Dsseldorf
Installation of adapted control program
on site
Additional DC converter
Rewiring of brake resistor or
optionally new brake resistor*
Delivery of installation material
Adaptation of documentation
Assembly and commissioning on site

*) New brake resistor is required, if current

brake resistor is not suitable for rewiring.

Dynamic brake resistor upgrade 33

 Dynamic brake resistor upgrade

Replacement of conventional brake

resistors by dynamic brake resistors

Advantages:
Significant reduced diesel consumption
Reduced noise emissions due to
constant diesel motor operation
No black smoke emissions Quotation lead time approx. 1 week
Delivery lead time up to 5 weeks
Installation time approx. 5 days
Price range 22,000 - 48,000*
Travelling costs, additional
hotel, expenses,
*) depending on crane type and variant and whether
or not the brake resistor has to be replaced

Significant reduced fuel consumption

Upgrade of green features
Dynamic brake resistor upgrade 34
Crane Data System (CDS)
Retrofit

Design freeze 7 cranes are prepared for CDS

installation
Standardised retrofit is available for cranes with
IPC of generation GPT 30 or higher
Retrofit for other cranes available on request

Scope of supply
CDS hardware
CDS server and system setup Quotation lead time approx. 1 week
Delivery lead time up to 5 weeks*
System contract for 3 years, incl. free updates
Installation time on site approx. 2 days
Assembly of CDS

Responsibility of customer
Provision of 3G mobile SIM card
*) after receiving 3G mobile SIM card in Dsseldorf

Real time data tool for management and operations

Enhances maintenance team with features like email alert and reports
35
Relocation as an all-in-one package

Transport solutions including: Equipment transported

Project planning completely assembled
Transport engineering partly assembled
Dismantling in assembly groups
Loading
Shipping
Unloading

36
Rail Welding / Rail Grinding
For Ship-to-Shore Cranes

37
Terex Port Solutions repairs

Welding Repairs Replacements

Welding of cracks in Deposition welding and Slewing rings

steelworks drilling of boom connection Luffing cylinders
Repair and welding of points Propping cylinders
boom Milling of contact surfaces Tower cab
Axles

38
Holistic service from a single source
Service packages and
outsourcing partners

Crane transport Assembly and

commissioning

General overhauls Professional Crane

Inspections (PCI)
and maintenance
contracts

Terex Port Solutions offers service

for the entire product lifecycle
Upgrades and retrofits

Repairs

Spare parts supply

39